Operating Manual - Dartmouth College

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Operating Manual - Dartmouth College
DENTON VACUUM, LLC
®
Explorer 14
Cryo System
Dartmouth College
Job # 43137
OPERATING MANUAL
1259 NORTH CHURCH STREET
MOORESTOWN, NJ 08057
856-439-9100
FAX: 856-439-9111
DARTMOUTH COLLEGE, #43137
TABLE OF CONTENTS
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Table of Contents
Section
Page
Equipment List, Serial Numbers and Vendor Manuals ..................................................................... A
1.
Introduction.................................................................................................................................... 1-1
2.
Safety Warnings ............................................................................................................................ 2-1
2.1 Mechanical Requirements........................................................................................................... 2-1
2.2 Electrical Standards ..................................................................................................................... 2-1
2.3 Safety Interlocks........................................................................................................................... 2-2
2.4 Moving Parts ................................................................................................................................ 2-2
2.5 Power Systems ............................................................................................................................ 2-2
2.6 Environmental Conditions ........................................................................................................... 2-2
2.7 Safety Symbols ............................................................................................................................ 2-2
3. Summary Specifications .............................................................................................................. 3-1
3.1 Deposition Chamber.................................................................................................................... 3-1
3.2 Pumping System.......................................................................................................................... 3-2
3.3 Vacuum Gauging & Gas Control ................................................................................................ 3-3
3.4 Cabinet ......................................................................................................................................... 3-3
3.5 Sputter Source ............................................................................................................................. 3-4
3.5.1
DC Power Gun Supply ......................................................................................................... 3-4
3.6 Substrate Stage ........................................................................................................................... 3-4
3.6.1
Substrate Stage RF Bias Power Supply ............................................................................. 3-5
3.6.2
Substrate Heat ...................................................................................................................... 3-5
3.7 Deposition Control.......................................................................................................................... 3-5
3.8 System Automation ........................................................................................................................ 3-6
3.9 Utility Requirements ....................................................................................................................... 3-6
I
DARTMOUTH COLLEGE, #43137
TABLE OF CONTENTS
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
3.10 System Documentation.................................................................................................................. 3-7
3.11 Mechanical Requirements ............................................................................................................. 3-7
3.12 Electrical Standards ....................................................................................................................... 3-8
3.12.1 Safety Interlocks.................................................................................................................... 3-8
3.12.2 Moving Parts ......................................................................................................................... 3-8
3.12.3 Power Systems..................................................................................................................... 3-9
4.0 System Acceptance Test ................................................................................................................ 3-9
4.1 Hardware Review..................................................................................................................... 3-9
4.2 Vacuum Performance .............................................................................................................. 3-9
4.2.1
Pumpdown and Ultimate Vacuum ............................................................................ 3-9
4.2.2
Pressure Rise Documentation ................................................................................3-10
4.3 Manual System Control ........................................................................................................ 3-11
4.3.1
Pumps, Valves, Rotation and Shutters................................................................... 3-11
4.3.2
Manual Substrate Rotation...................................................................................... 3-11
4.3.3
Process Gas............................................................................................................. 3-11
4.3.4
Manual Deposition Operation ................................................................................. 3-12
4.4 Manual Substrate Cooling.................................................................................................... 3-12
4.5 Manual Substrate Heating.................................................................................................... 3-13
4.6 Auto Processing.................................................................................................................... 3-13
4.6.1
Resident Baseline Programs ................................................................................... 3-13
4.6.2
Automatic Sputtering (Cathodes 1, 2, 3) ................................................................. 3-14
4.6.3
Demonstration of Process Control During Deposition Layers/Multi-Layers/Multi
Steps
........................................................................................................................................................ 3-14
4.7 System Interlocks.................................................................................................................. 3-15
TABLES:
Leakup and Ultimate Vacuum
Pumpdown and Ultimate Vacuum
Thickness Uniformity
II
DARTMOUTH COLLEGE, #43137
TABLE OF CONTENTS
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
4. Utility Requirements ..................................................................................................................... 4-1
4.1 Utilities........................................................................................................................................... 4-1
4.2 System Grounding Practice for RF and E-Beam Systems ....................................................... 4-1
4.3 Mechanical Requirements........................................................................................................... 4-2
4.4 Electrical Standards ..................................................................................................................... 4-2
5. Software Overview ........................................................................................................................ 5-1
5.1 Control System............................................................................................................................. 5-1
5.2 Overview Screen.......................................................................................................................... 5-3
5.3 Top Overview Bar ........................................................................................................................ 5-4
5.4 Left Overview Screen .................................................................................................................. 5-4
5.4.1 Auto............................................................................................................................................ 5-5
5.4.1.1 Manual.................................................................................................................................... 5-5
5.4.1.2 Service.................................................................................................................................... 5-5
5.4.2 Interlocks ................................................................................................................................... 5-6
5.4.3 Auto Deposit Info ...................................................................................................................... 5-6
5.5 Right Overview Screen (Sputter Status & Control).................................................................... 5-7
Sputter Status and Control Screen .................................................................................................... 5-8
RF Bias Control Screen.................................................................................................................... 5-10
Substrate Heat Control Screen ........................................................................................................ 5-11
6. System Operation.......................................................................................................................... 6-1
6.1 System Startup/Cryopump Regeneration, Manual.................................................................... 6-1
6.2 Cryo Pump Regeneration – Automatic Mode (Recipe Screen)................................................ 6-3
6.3 Cryo Pump Regeneration Description – Automatic Mode ........................................................ 6-5
6.4 Main Chamber Pumping – Automatic Mode .............................................................................. 6-6
6.5 Main Chamber Pumping – Manual Mode .................................................................................. 6-7
6.6 Main Chambering Venting – Automatic Mode ........................................................................... 6-8
III
DARTMOUTH COLLEGE, #43137
TABLE OF CONTENTS
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
6.7 Main Chamber Venting Description – Automatic Mode ............................................................ 6-9
6.8 Main Chamber Venting – Manual Mode...................................................................................6-10
6.9 Substrate Heat – Manual Mode ................................................................................................ 6-10
6.10 Gas Control for Sputtering – Manual Mode ............................................................................ 6-11
6.11 RF Bias – Manual Mode........................................................................................................... 6-13
6.12 Sputtering – Manual Mode....................................................................................................... 6-14
6.13 Auto Sputter – Automatic Mode (Recipe Screen)................................................................... 6-15
Typical Program Screen ................................................................................................................... 6-16
Overview Auto Process Screen ....................................................................................................... 6-22
6.14 Auto Sputter Description – Automatic Mode........................................................................... 6-23
7. System Alarms............................................................................................................................... 7-1
7.1 Programmable Tolerance Alarms............................................................................................... 7-1
8. System Interlocks.......................................................................................................................... 8-1
9. System Maintenance…………………………………………………………………………………..9-1
9.1 ProcessPro Total Solution Server ........................................................................................... 9-1
9.2 Chamber Cleaning .................................................................................................................... 9-2
9.3 Mechanical Pump...................................................................................................................... 9-2
9.4 Cryogenic Pump........................................................................................................................ 9-2
9.5 High Vacuum Valve................................................................................................................... 9-2
9.6 Rotary Feedthroughs ................................................................................................................ 9-3
9.7 Overall System Maintenance.................................................................................................... 9-3
9.8 Fuse Ratings ............................................................................................................................. 9-3
10. Troubleshooting.......................................................................................................................... 10-1
10.1 Safety Warnings........................................................................................................................ 10-1
10.2 Required Tools.......................................................................................................................... 10-2
10.3 Vacuum System Control Rack................................................................................................. 10-3
IV
DARTMOUTH COLLEGE, #43137
TABLE OF CONTENTS
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
10.4 Valves and Shutters.................................................................................................................. 10-4
10.5 Rotation ..................................................................................................................................... 10-6
10.6 Mechanical Pump ..................................................................................................................... 10-7
10.7 Substrate Heat .......................................................................................................................... 10-8
10.8 Summary.................................................................................................................................10-10
11. Electrical Schematics ................................................................................................................. 11-1
12. Mechanical Drawings ................................................................................................................. 12-1
13. Spare Parts Lists......................................................................................................................... 13-1
V
DARTMOUTH COLLEGE, JOB # 43137
EQUIPMENT LIST, SERIAL NUMBERS, VENDOR MANUALS
DENTON VACUUM LLC
EXPLORER 14 CRYO SYSTEM
EQUIPMENT LIST, SERIAL NUMBERS AND VENDOR MANUALS
MANUAL
EQUIPMENT
Pumping Control
Mechanical Pump
Pfeiffer
M p/n PK 800 170 BN/D 9910
M m/n DU010
S/N
20036959
Manual Provided
Cryo Pump
CTI Cryogenics
M p/n n/a
M m/n CTI-8
S/N E03149862
Manual Provided
Cryo Pump Compressor
CTI Cryogenics
M p/n n/a
M m/n 8300
S/N G03160384
Manual Provided
Computer Control
Computer Monitor
Samsung Digital
M p/n n/a
M m/n Syncmaster LCD
S/N 66-15H4NT608461M
Manual Provided
Computer
Dell Computer
M p/n n/a
M m/n n/a
S/N 6D1NZ21
Manual Provided
3-Com Lan Modem
M p/n 3C886
M m/n 3C886
S/N X25DA766BC
Manual Provided
A
DARTMOUTH COLLEGE, JOB # 43137
EQUIPMENT LIST, SERIAL NUMBERS, VENDOR MANUALS
DENTON VACUUM LLC
EXPLORER 14 CRYO SYSTEM
EQUIPMENT LIST, SERIAL NUMBERS AND VENDOR MANUALS
MANUAL
EQUIPMENT
DC Power Supply
Xantrex
M p/n n/a
M m/n XFR 1200
S/N
64185
Manual Provided
RF Power Supply
Seren
M p/n n/a
M m/n R600
S/N
R600-643613R2
Manual Provided
Matching Network
Seren
M p/n n/a
M m/n AT-6
S/N
AT-6-0022
Manual Provided
Matching Network Controller
Seren
M p/n n/a
M m/n MC2
S/N
MC2-0040
Manual Provided
Sputtering Source
US Gun Inc.
M p/n n/a
M m/n MAK 2"
#1 S/N 2303H0607
#2 S/N 2303H0609
#3 S/N 2306-0801
Manual Provided
B
DARTMOUTH COLLEGE, JOB # 43137
EQUIPMENT LIST, SERIAL NUMBERS, VENDOR MANUALS
DENTON VACUUM LLC
EXPLORER 14 CRYO SYSTEM
Vendor Manual List
DARTMOUTH COLLEGE
EXPLORER® 14
Job #: 43137
Company
Manual
PFEIFFER VACUUM
MANUAL FOR ROTARY VANE PUMP (PK 800 170 BN/D
9910)
XANTREX
OPERATING MANUAL FOR XFR 1200 POWER SUPPLY
MKS INSTRUMENTS
INSTRUCTION MANUAL FOR MASS FLOW CONTROLLER
& METER
SEREN
OPERATING MANUAL FOR POWER SUPPLY R600
SEREN
OPERATING MANUAL FOR MATCHING NETWORK AT-6
SEREN
OPERATING MANUAL FOR MATCHING NETWORK
CONTROLLER MC2
CTI-CRYOGENICS
OPERATING, INSTALLATION, & MAINTENANCE MANUAL
FOR CRYO-TORR HIGH VACUUM PUMP WITH
COMPRESSOR
PC ANYWHERE
MANUAL FOR PC ANYWHERE ON CD
GE FANUC
LICENSE KEY FOR CIMPLICITY ON CD
SAMSUNG DIGITAL
USER’S GUIDE FOR SYNCMASTER MONITOR WITH
INSTALLATIONMANUAL FOR MONITOR DRIVE
3COM
NETWORK ASSISTANT FOR OFFICE CONNECT ON CD
WEIDMULLER
INSTALLATION GUIDE FOR TERMINAL BLOCK
WEIDMULLER
INSTALLATION GUIDE FOR SWITCHMODE POWER
SUPPLY
HIGH VACUUM
APPARATUS
INSPECTION & TEST SHEET FOR GATE VALVE
WHITMAN
CONTROLS
INSTALLATION MANUAL FOR VACUUM & PRESSURE
SWITCH
SKINNER VALVE
INSTALLATION, OPERATING, & MAINTENANCE
INSTRUCTION FOR SOLENOID VALVE
PROTUES
INDUSTRIES
MANUAL FOR 100 SERIES FLOW SWITCH
US INC.
OPERATING MANUALS FOR MAK SPUTTERING SOURCE
RELIANCE
ELECTRIC
INSTRUCTION MANUAL FOR DC3E DC DRICE (D2-3452)
C
DARTMOUTH COLLEGE, JOB # 43137
INTRODUCTION
1.
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Introduction
The Denton Explorer 14 Sputtering System is a customized vacuum deposition system
designed for thin film research applications. It features a “box coater” design that provides
easy access to substrates, sources, and instrumentation while maintaining excellent
pumping characteristics. This system is designed to simplify the geometry necessary for
coordination of multiple sputter sources, biasable substrate table, and Substrate heat.
Because Denton uses the finest available subsystems and components, the system is
highly reliable and durable. The system’s inherent flexibility allows the operation of
multiple sputter sources and RF Bias source, the ability to heat and rotate the substrates,
and automatically control the process.
The Explorer 14 system is fully automatic and is controlled by a computer with a mouse
running GE Cimplicity PC control software combined with a GE VERSAMAX
programmable logic controller. The computer, keyboard, power supplies, and switches
are installed in a single electrical control cabinet. The cabinet is conveniently located next
to the chamber on a unit frame for easy installation, observation and operation.
The system offers you a myriad of thin film process options. However, it is important to
note that with all of this system’s potential there exists safety considerations. Individuals
who are to operate, service, or maintain this system should familiarize themselves
with this manual.
If this equipment is used in a manner not specified by Denton Vacuum, the
protection provided by the equipment may be impaired.
1-1
DARTMOUTH COLLEGE, # 43137
SAFETY WARNINGS
2.
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
SAFETY WARNINGS
This vacuum deposition system is comprised of a number of complex
subsystems
LETHAL VOLTAGES, HIGH TEMPERATURES, HIGH PRESSURES
AND POWERFUL MECHANICAL DRIVE MECHANISMS ARE PRESENT THROUGHOUT
THE SYSTEM.
Every attempt has been made to safeguard operating and maintenance personnel. Interlocking
of subsystems provides a high degree of operator safety.
SYSTEM/SOFTWARE INTERLOCKS SHOULD NEVER BE DEFEATED UNLESS
SERVICING OF THE SYSTEM REQUIRES TEMPORARY INTERLOCK OVERRIDES.
HARDWIRED SAFETY INTERLOCKS MUST NEVER BE DEFEATED.
All safety/software interlocks should be returned to operational status when problems have
been corrected.
Operating and maintenance manuals have been provided and should be thoroughly
understood before any operations are contemplated.
THE SYSTEM SHOULD BE OPERATED ONLY BY PERSONNEL WITH PROPER
TRAINING AND PROCESS EXPERIENCE.
IF THE EQUIPMENTS ARE IN A MANNER NOT SPECIFIED BY THE MANUFACTURERS,
THE PROTECTIONS PROVIDED BY THE EQUIPMENTS MAY BE IMPAIRED.
2.1 MECHANICAL REQUIREMENTS
Equipment is to be designed to industrial machine tool standards and where applicable to GM
Electronics Specifications for Industrial and Clean Room Equipment (WEMA-8403, 4/15/87)
Commercially purchased components are new and of industrial quality. All ferrous or aluminum metals
are properly finished to prevent corrosion or oxidation. All pneumatic lines, valves, cylinders and flow
controls are to operate at a minimum pressure of 90 psi and a maximum pressure of 110 psi.
2.2 ELECTRICAL STANDARDS
All electrical equipment is in accordance with the National Electric Code and where applicable General
Motors ES1 Basic electrical standard. All signal power is isolated from system power; proper shielding
and routing practices must be followed. All electrical, electronic, and optical sensors must be
adequately protected from process contamination.
Three-phase power distribution is 208 VAC, 60 cycle (all equipment with three phase inputs must be
supplied for this voltage); single-phase inputs are 208 VAC and 120 VAC. All equipment has panelized
control with a single entrance protection by heavy duty disconnect switch. The disconnect switch has a
“lockout” provision to ensure that no electrical power can be delivered to the system during
maintenance operations.
2-1
DARTMOUTH COLLEGE, # 43137
SAFETY WARNINGS
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
2.3 SAFETY INTERLOCKS
The system is equipped with a hardwired safety interlock system, which fully protects operators and
maintenance personnel from injury. The following hardwired interlocks are provided:
Cathode Power: Vacuum safety bellows switch and chamber door.
Heat Power: Vacuum safety bellows switch and chamber door.
All hardwired safety interlock status will be duplicated by system controller “software” interlocks. The
status of all hardwired interlocks is displayed on the control screen.
2.4 MOVING PARTS
Sliding surfaces and pinch points are fully guarded to prevent injury to operators and maintenance
personnel. In the event of a power failure, all moving parts come to their home position without damage
to the equipment or injury to operators and/or maintenance personnel.
2.5 POWER SYSTEMS
In the event of an interlock dropout or power failure, all power to the internal sources of energy is
interrupted. When power is restored, or an interlock is satisfied, a hard, manual reset of the effected
subsystem will be required. High voltage transformers, vacuum feedthroughs and interconnecting
cabling is enclosed in watertight enclosures (NEMA 12 rating or better).
2.6 ENVIRONMENTAL CONDITIONS
The system is designed and intended for use in the following environmental conditions. If all
specifications are not met, system components may malfunction and can possibly cause injuries.
•
•
•
•
•
•
Altitude up to 2000m
Temperature range from 5 to 40o C
Maximum relative humidity 80% for temperature up to 31o C decreasing linearity to 50% relative
humidity at 40 o C
Mains supply voltage fluctuations not to exceed +/-10% of the nominal voltage
Other supply voltage fluctuations as stated by the manufacturer
Pollution degree 2 in accordance with IEC 664
2.7 SAFETY SYMBOLS
CAUTION: Risk of Electrical Shock
CAUTION: This symbol is intended to alert the user to the presence
of important operation & maintenance instructions in this manual.
Protective Conductor Terminal: this symbol indicates where the
protective earth ground is connected.
2-2
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
DARTMOUTH COLLEGE
EXPLORER®-14 T/A COATING SYSTEM
SUMMARY SPECIFICATION
&
ACCEPTANCE TEST PROTOCOL
(April 23, 2003)
Job # 43137
REVISION A (5-11-03)
3. SUMMARY SPECIFICATION:
3.1.
1.)
2.)
3.)
4.)
5.)
6.)
DEPOSITION CHAMBER:
Discovery SJ/14; 12” (high) x 14” (wide) x 14”(deep).
304 stainless steel construction (painted).
Large-profile, front-loading door; 12”(high) x 13”(wide).
One complete set of removable, stainless steel shields (multi-piece construction
to facilitate removal and installation).
Rear mounted pumping plenum assembly.
Baseplate bolted to chamber assembly.
3-1
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Multi-piece plenum mounted at substrate stage level.
The following penetrations are provided:
Baseplate:
- ISO 200 flange (center mounted for substrate stage rotation/bias, heater
electrical feedthrus, and T.C. probe),
Sidewall:
- (3) 2.75” CF flanges (3-blank, and
- (1) 0.25” compression seal (gas inlet).
- (2) 10” O.D. CF flange ( 1 blanked for future use) (1 for pump port)
- (1) 16 – NW (capacitance manometer)
- (1) 25-NW (Full Range Gauge)
7.)
8.)
Door:
-
(1) optically shielded 4.0" diameter viewport (front door) to permit
unrestricted viewing of all installed deposition sources and substrate
fixturing.
-
(1) ½” Compression Seal (spare gas inlet),
(3) ISO 160 cathode assembly mounting ports,
(3) cathode mounting flange with the following penetrations:
(1) .75” compression seal (sputter cathode), and
(1) 0.25” (shutter rotary motion feedthrough).
Top-plate:
Pumping Plenum:
- 10” O.D. CF port extension flange,
- (1) NW-25
- (1) 8” I.D. mitered elbow w/ 10” O.D. CF flanges
3.2.
PUMPING SYSTEM:
•
•
CTI Cryogenics CT-8 cryogenic pump.
CTI Cryogenics water-cooled compressor. 10’ Helium lines.
•
Pfeiffer Duo 10 two-stage, rotary vane pump (7 CFM):
9.)
i.
Inlet and exhaust filter
High Vacuum Valve: Three position gate valve;10” CF flanges.
3-2
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Roughing Valve: NW25 bellows-sealed, electro-pneumatic, roughing
10.)
valve.
Regen Valve: NW25 bellows-sealed, electro-pneumatic, Regen valve.
Cryopump Purge Valve: CTI purge valve package.
Vent Valve: 0.25” VCO, bellows-sealed, electro-pneumatic, vent valve.
Leak Check Valve: Manual ball valve mounted in foreline.
Foreline filter: CT-103.
11.)
12.)
13.)
14.)
15.)
3.3.
•
•
•
•
VACUUM GAUGING & GAS CONTROL:
(2) Inficon BPG 400 combination Bayard-Alpert ionization gauge
transmitters (ISO-25 flanging; main chamber and high vacuum valve
body/pump side).
(1) Inficon SKY Capacitance manometer gauge for process control (chamber).
(2) MKS 2179A Mass Flow controller:
i. 100 SCCM with CB 259-5 cables,
ii. integrated to system PC. with
iii. PID control
Gas manifold for (4) positions, (2 will be VCR blanked)
3.4.
CABINET:
Fully-enclosed system cabinet (on casters) with a full opening service
door:
16.)
i.
(1)
-
Main cabinet:
30” (wide) x 27 3/4” (deep) x 39” (high) steel cabinetry,
Aluminum swing door with locker, and
All controls and electrics mounted on service door to facilitate system
maintenance and troubleshooting activities.
ii.
(1)
(1)
Extend cabinet:
19” (wide) x 27 3/4” (deep) x 39” (high) steel cabinetry, and
Aluminum swing door with locker.
Control cabinet:
a. 19” (wide) x 23” (deep) x 17 3/4” (high) steel cabinetry.
iii.
3-3
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
3.5.
•
•
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
SPUTTER SOURCE:
(3) 2.0” diameter, internal stalk-mount, “US Gun”, planar magnetron sputter sources:
i.
RF/DC capability,
ii.
Variable source to substrate distance,
iii.
Clamp/bond target compatibility, and
(3) independent, electro-pneumatic source shutters (cylinder mounted air flowrate
control) interfaced to system PLC for remote open/close operation.
3.5.1. DC POWER GUN SUPPLY:
•
•
•
(1) Xantrex 1 kW DC power supplies:
i.
(1) switchable between Source #2 and #3,
ii.
Hardwired safety interlock (chamber door, vacuum bellows safety
switch, cathode water),
iii.
Interfaced to system controller for remote on/off operation and
setpoint control.
(1) Seren 600 watt R600 Generator with MC-2 controller and match tuning network
AT-6
iv.
(1) dedicated to Source #1,
v.
Hardwired safety interlock (chamber door, vacuum bellows safety
switch, cathode water),
vi.
Interfaced to system controller for remote on/off operation and
setpoint control.
Cooling water flow sense on cathode's dedicated cooling water circuit (safety
interlock). Proteus sensor mounted on rear of cabinet.
3.6.
•
•
•
SUBSTRATE STAGE:
RF-bias substrate stage :
i.
6.0" substrate platen; pre-machined to accept DVI 150 mm sample
transfer holder.
ii.
Table premachined for water cooling circuit
(2) DVI 150 sample transfer holders (blank).
I (1) machined SST blank
Ii (1) machined Copper blank
(1) DVI high performance, water-cooled, RF-biasable rotary motion feedthrough, ISO
200 NW flanging.
3-4
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
•
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
(1) direct-drive, compact, gear motor:
i.
Speed adjust (0-20 RPM) via set point control, and
ii.
Interfaced to system PLC for remote on/off operation.
3.6.1. SUBSTRATE STAGE RF-BIAS POWER SUPPLY:
NOTE: ( OPTION NOT SELECTED, SYSTEM WILL BE CONFIGURED
WITH ALL NECESSARY HARDWARE/ MECHANICAL, ELE, AND
SOFTWARE FOR FIELD INSTALLATION OF POWER SUPPLY AT A LATER
DATE)
•
(1) Seren R300 power supply (300 watt output), coupled to a Seren automatic match
network (air cooled operation):
i.
Hardwired safety interlock (chamber door, vacuum bellows safety
switch),
ii.
Interfaced to system controller for remote on/off operation and
setpoint control, and
iii.
Dedicated to RF bias stage.
3.6.2 SUBSTRATE HEAT:
•
•
•
•
(2) 1.0 kW, backside quartz heater arrays with reflector and deposition shield.
208/110 VAC step-down/isolation transformer to minimize possibility of spurious
glow discharges and feedback from sputter power supplies.
PID temperature control system:
i.
Interfaced to system controller for remote on/off, setpoint.
(1) sheathed thermocouple positioned internally in chamber.
3.7.
•
DEPOSITION CONTROL:
PC control for all power supply parameters. Thickness will be based on time and power
supply control parameters.
3-5
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
3.8.
•
•
•
•
•
•
•
•
•
•
•
17.)
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
SYSTEM AUTOMATION:
Industrial PC (Windows XP® Professional operating system); flat-panel display.
ProcessPro® control software configured for specific delivered hardware:
i.
activation of pumps, valves, deposition sources, subsystems, gauging,
gas/flow control, setpoints, and automatic process sequence
activation.
GE-Fanuc VERSAMAX programmable logic controller interfaced to system host
computer.
Remote access via user-supplied dedicated analog phone line.
Full remote setpoint capability:
i.
Gas 1 & 2 flowrates,-upgradeable to (4) total MFC’s
ii.
Substrate temperature,
iii.
DC power supply setpoints,
iv.
RF power supply setpoints, and
v.
Active cathodes.
vi.
Future RF Bias control
Multiple operation modes:
i.
Manual,
ii.
Automatic,
iii.
Maintenance, and
iv.
Automatic process sequence generation and editing
v.
Up to 250 process steps per recipe
Recipe storage for up to 799.
Data logging for process parameters
Alarm messaging and interlock notification
Remote recipe writing capabilities
Automatic process sequences delivered:
i.
Autopump,
ii.
Autovent,
iii.
Multi layer deposition Recipes
iv.
Cryo Regen process
3.9. UTILITY REQUIREMENTS:
Electrical:
- 208 VAC (+/- 5 %), 60 Hz, single-phase, 3 wire, 70 Amps. (estimated).
- Actual electrical requirements determined when schematics are
completed.
3-6
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Panelized control with single entrance protection by a heavy duty
disconnect switch with "lockout" provision, provided by DVI.
Water:
- (6) GPM, 60-80 °F, 40-60 psig differentials between supply and return (60
psig maximum inlet pressure).
- Water distribution:
1) Cathode #1, #2, and #3, and
2) CTI 8200 water cooled compressor.
3) Open drain for cooling table water exhaust
4) Electric solenoid valve control for “heating and cooling”
processes on substrate table. PC interfaced.
Air:
- Normal dry shop air, 90-110 psi (system valve operation).
- Stand-alone air manifold positioned above the water manifold; solenoid
valves incorporating removable plug-type electrical connections.
Argon (99.9995 % purity):
- 3-15 psi (process gas).
-
18.)
19.)
20.)
21.)
Nitrogen (optional):
- Preferentially evaporated from a liquid source.
- 3-15 psi (chamber venting).
3.10. SYSTEM DOCUMENTATION:
22.)
Operating instruction manual; to include preventive maintenance
procedures/timetable, troubleshooting guides, and spare parts listing (CD-ROM).
One complete set of sub-assembly vendor manuals.
One complete set of electrical schematics (CD-ROM with viewer).
One complete set of mechanical drawings necessary for system maintenance and
repair (CD-ROM).
3.11. MECHANICAL REQUIREMENTS:
23.)
24.)
25.)
26.)
27.)
28.)
Commercially purchased components will be new, of industrial quality and
demonstrated "best in class" availability.
All ferrous or aluminum metals will have proper finishes to prevent corrosion or
oxidation.
All pneumatic lines, valves, cylinders and flow controls are designed to operate at
a minimum pressure of 80 psi and a maximum pressure of 110 psi.
3-7
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
3.12. ELECTRICAL STANDARDS:
All electrical equipment shall be compliant with NEC (US) and CE code and
regulations.
All signal power will be isolated from system power; proper shielding and routing
practices must be followed.
All electrical, electronic, and optical sensors must be adequately protected from
process contamination.
Three-phase distribution is 208 VAC, 60 cycle (all equipment with three phase
inputs must be supplied for this voltage); single-phase inputs shall be 208/220
VAC and 120 VAC.
All equipment shall have panelized control with a single entrance protection by a
heavy duty disconnect switch. The disconnect switch will have a "lockout"
provision to ensure that no electrical power can be delivered to the system
during maintenance operations.
3.12.1.SAFETY INTERLOCKS:
29.)
30.)
31.)
32.)
33.)
34.)
35.)
36.)
37.)
38.)
The system will be equipped with a hardwired safety interlock system, which fully
protects operators and maintenance personnel from personal injury. The
following hardwired interlocks will be provided:
Resistance Evaporation Power: Vacuum bellows switch and chamber door, and
Heat Power: Vacuum safety bellows switch and chamber door.
The status of all hardwired safety interlocks will be displayed to the system
operator(s) at all times.
System controller “software” interlocks will duplicate all hardwired safety
interlock status.
3.12.2.MOVING PARTS:
Sliding surfaces and pinch points must be fully guarded to prevent injury to
operators and maintenance personnel.
In the event of a power failure, all moving parts are to come to a complete stop.
Upon initiating a restart cycle, all moving parts are to proceed to their home
position without damage to the equipment or injury to operations and/or
maintenance personnel.
3-8
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
3.12.3.POWER SYSTEMS:
39.)
40.)
4.
In the event of an interlock dropout or power failure, all power to internal
sources of energy (heat and resistance evaporation power supply) will be
interrupted. When power is restored, or an interlock is satisfied, a hard, manual
reset of the affected subsystem will be required.
High voltage transformers, vacuum feedthroughs and interconnecting cabling will
be enclosed in water-tight enclosures.
SYSTEM ACCEPTANCE TEST
4.1.
( DVI Factory)
HARDWARE REVIEW:
All stated equipment, and subsystems detailed in Summary Specification were present
and accounted for.
WITNESS:
___________________
Vacuum LLC
4.2.
___________________
____________ Denton
Dartmouth College
Date
VACUUM PERFORMANCE:
4.2.1. PUMPDOWN AND ULTIMATE VACUUM:
1.)
2.)
Clean, dry and empty system pumped overnight (12 hrs minimum).
Chamber to demonstrate ultimate pressure of < 8.0 x 10-8 torr .
3-9
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
3.)
4.)
5.)
6.)
7.)
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Chamber vented to atmosphere with dry N2 gas.
Chamber door to be kept closed. (to avoid uncontrolled environmental
conditions)
Chamber door closed and system pumped into high vacuum status using
"AUTOPUMP" automatic pumping sequence.
Chamber pressure to be recorded at 30-second intervals during roughing and at
one-minute intervals after high vacuum crossover.
Data to be recorded for a period of 30 minutes.
WITNESS:
___________________
Vacuum LLC
___________________
____________ Denton
Dartmouth College
Date
4.2.2. PRESSURE RISE DOCUMENTATION:
1.) Clean, dry and empty system pumped overnight (12 hrs minimum).
2.) High vacuum valve and high vacuum bypass valve closed.
3.)
Rise in chamber pressure recorded at one-minute intervals for a period of thirty
minutes.
4.)
Data presented in both a tabular and graphical format.
WITNESS:
___________________
Vacuum LLC
___________________
____________ Denton
Dartmouth College
Date
3-10
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
4.3.
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
MANUAL SYSTEM CONTROL:
4.3.1. PUMPS, VALVES, ROTATION AND SHUTTERS:
1.)
Individual pump, valve, rotation, and shutter icons selected and then enabled
(subject to pre-defined manual mode interlocks).
WITNESS:
___________________
Vacuum LLC
___________________
Dartmouth College
____________ Denton
Date
4.3.2. MANUAL SUBSTRATE ROTATION:
1.) Demonstrate rotation control up to 20 RPM
4.3.3. PROCESS GAS:
1.)
2.)
3.)
4.)
5.)
High vacuum system status.
Process gas isolation valve opened.
Mass flow controller adjusted to achieve a chamber pressure of 5 mtorr.
Process gas isolation valve closed.
Repeat for both mass flow controllers.
WITNESS:
___________________
Vacuum LLC
___________________
Dartmouth College
Date
3-11
____________ Denton
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
4.3.4.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
MANUAL DEPOSITION OPERATION:
All test targets (clamp-type) installed; source to substrate distance of 4.00"
established.
Test coupons (supplied by DVI) placed in sample holder.
Chamber pumped into high vacuum status.
Substrate rotation energized.
Active cathode "#1" selected via PC.
Argon introduced into main chamber; process pressure of 5.0 mtorr attained.
RF setpoint of 150 W programmed into power supply.
RF power supply energized.
Target soaked at 150 W for 1 minute.
Cathode shutter opened.
RF discharge sustained for 5 minutes.
During discharge, demonstrate operation at system pressures of 1,3 & 5,
millitorr.
Cathode shutter closed.
RF power supply de-energized.
Argon process gas isolation valve closed.
Repeat for DC cathodes # 2, 3.
WITNESS:
___________________
Vacuum LLC
4.4.
___________________
Dartmouth College
____________ Denton
Date
MANUAL SUBSTRATE COOLING:
i. Demonstrate water flow thru table assembly during a 5 minute film
deposition
ii. Demonstrate water flow interlock for heat process to show water
circuit exhaust.
3-12
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
4.5.
1)
2)
3)
4)
5)
6)
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
MANUAL SUBSTRATE HEATING:
Clean dry and empty system; high vacuum status.
Remote temperature setpoint input into parameter field (300 degrees Centigrade).
Substrate rotation energized.
Heater power energized.
Substrate temperature (measured by primary internal chamber thermocouple)
stabilized at setpoint, +/- 3 degrees, soak for 15 minutes.
Heater power de-energized.
WITNESS:
_______________________
Denton Vacuum LLC
4.6.
1.)
2.)
_______________________
Dartmouth College
__________
Date
AUTO PROCESSING:
4.6.1. RESIDENT BASELINE PROGRAMS:
Automatic chamber pumping from atmospheric pressure to high vacuum status
demonstrated using resident “AUTOPUMP” process sequence.
Automatic chamber venting from high vacuum status to atmospheric pressure
demonstrated using resident “AUTOVENT” process sequence.
WITNESS:
___________________
Vacuum LLC
___________________
____________ Denton
Dartmouth College
Date
3-13
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
4.6.2. AUTOMATIC SPUTTERING (CATHODES 1 , 2, 3):
1)
All test targets (clamp-type) installed, (TBD.); source to substrate distance of
4.00" established.
Test samples placed on sample holder.
Chamber pumped into high vacuum status.
RF setpoint of 150 W programmed into power supply, cathode # 1.
Argon flowrate programmed into system controller.
Activate cathode #1, selected via system controller.
Pre-sputter time period programmed into system timer.
Sputter time period programmed into system timer.
Automatic sputter process initiated via PC.
Steps 1 through 9 repeated for DC cathodes #2, 3.
Thickness non-uniformity less than +/- 5.0 % demonstrated over 150 mm
substrate diameter.
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
Definitions:
"+/- Thickness Non-Uniformity" = ((Tmax-Tmin)/Tavg)/2)*100
where:
Tmax = Maximum thickness recorded within measurement area
Tmin = Minimum thickness recorded within measurement area
Tavg = Average thickness recorded within measurement area
WITNESS:
___________________
Denton Vacuum LLC
4.6.3
___________________
Dartmouth College
____________
Date
Demonstration Of Process Control During Deposition Layers/
Multi-layers/ Multi Steps.
3-14
DARTMOUTH COLLEGE, # 43137
SUMMARY SPECIFICATIONS & ACCEPTANCE TEST PROTOCOL
1)
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
In an Automatic recipe run, demonstrate (3) layer film using each
source.
2)
In an Automatic recipe run, demonstrate a process run for
multiple steps beginning with: Chamber pump, co-sputter deposition with
cooling, co-sputter deposition with heating, substrate cool-down step, Chamber
vent.
In an Automatic recipe run, demonstrate process changes within
any given layer while maintaining a plasma at the source(s). This process run
will show the following parameter changes: Temperature/system gas
control/system pressure/deposition rate/co-sputter/source transition.
3)
WITNESS:
___________________
Denton Vacuum LLC
4.7
1.)
2.)
3.)
___________________
Dartmouth College
____________
Date
SYSTEM INTERLOCKS:
All system "soft" interlocks tested and functionality verified.
All system "hard" safety interlocks tested and functionality verified.
System Emergency-Stop tested and functionality verified.
WITNESS:
_______________________
Denton Vacuum LLC
_______________________
Dartmouth College
3-15
__________
Date
ACCEPTANCE TEST
VACUUM PERFORMANCE: LEAKUP AND ULTIMATE VACUUM
EXPLORER 14
Procedure:
1
2
3
4
DATE:
Clean, dry and empty system pumped overnight (12 hours minimum).
Base vacuum < thn 5.0 x 10-7 torr (with Ln2).
Close high vacuum valve.
Rise in chamber pressure recorded at one-minute intervals for a period of thirty minutes.
8/26/2003
ULTIMATE PRESSURE
Minute
Vacuum
(torr)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
3.3 x -6
6.2 x -6
9.5 x -6
1.3 x -5
1.7 x -5
2.1 x -5
2.6 x -5
3.4 x -5
3.8 x -5
4.2 x -5
4.7 x -5
5.1 x -5
5.6 x -5
6.0 x -5
6.5 x -5
6.9 x -5
7.4 x -5
7.9 x -5
8.3 x -5
8.8 x -5
9.3 x -5
9.8 x -5
1.0 x -4
1.1 x -4
1.1 x -4
1.2 x -4
1.2 x -4
1.3 x -4
1.3 x -4
1.4 x -4
Customer: Dartmouth College
JOB #
8.3 x -8
Minute
43137
DENTON AT
START VACUUM
HI VAC
Vacuum
(torr)
Minute
Vacuum
(torr)
Minute
Vacuum
(torr)
ACCEPTANCE TEST
VACUUM PERFORMANCE: PUMPDOWN AND ULTIMATE VACUUM
EXPLORER 14
Procedure:
1
2
3
4
5
6
DATE:
Clean, dry and empty system pumped overnight (12 hrs. minimum).
Chamber to demonstrate ultimate pressure of < 3.0E-7 torr LN Trap filled.
Chamber vented to atmosphere with dry N2 gas.
System pumped into high vacuum status using "AUTOPUMP" automatic pumping sequence.
Chamber to reach pressure of 150 mtorr (high vacuum crosover) in < 10 minutes after initiating
pumping cycle.
All pumpdown data to be recorded on one-minute intervals for a period of minutes.
8/18/2003
ULTIMATE PRESSURE
ROUGH
Minute
0.5
1
1.5
2
2.5
3
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Vacuum
(torr)
1.1 x +2
2.6 x +1
5.1 x +0
1.1 x +0
3.2 x -1
1.2 x -1
Customer: Dartmouth College
JOB #
7.3 x -8
Minute
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
5.7 x -6
3.2 x-6
2.2 x -6
1.8 x -6
1.5 x -6
1.3 x -6
1.2 x -6
1.0 x -6
9.5 x -7
8.8 x -7
8.1 x -7
7.8 x -7
7.3 x -7
7.0 x -7
6.7 x -7
6.4 x -7
6.1 x -7
5.9 x -7
5.6 x -7
5.4 x -7
5.2 x -7
5.1 x -7
4.9 x -7
4.7 x -7
4.6 x -7
4.5 x -7
4.4 x -7
DENTON AT
START VACUUM
HI VAC
HI-VAC
Vacuum
(torr)
43137
Minute
Vacuum
(torr)
Minute
Vacuum
(torr)
ACCEPTANCE TEST
Section 2.3.5
THICKNESS UNIFORMITY
=
Non Thickness Uniformity
(( T max - T min) / T avg / 2) x 100
Customer:
Dartmouth
Tmax
Tmin
Tavg
=
=
=
Maximum thickness recorded within useful fixture area
Minimum thickness recorded within useful fixture area
Average thickness recorded within useful fixture area
Specification:
DATE
TEST TYPE
+/- 5%
August 20, 2003
Test
Location on Planet
Run
Center
1.0
2.0
3.0
Avg.
%
C1
C2
C3
1250.0
3025.0
1675.0
1100.0
2905.0
1510.0
1135.0
3005.0
1455.0
1025.0
3065.0
1425.0
C1-1
C3-1
1120.0
1285.0
1065.0
1300.0
1150.0
1295.0
1160.0
1240.0
1127.5
3000.0
1516.3
#DIV/0!
1123.8
1280.0
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
9.98
2.67
8.24
#DIV/0!
4.23
2.34
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
CUSTOMER: Dartmouth College
JOB #43137
Avg. Avg.
Prog.
#1,#2 #3,#4 Max-Min Thk.
1161.7
2978.3
1546.7
#DIV/0!
1111.7
1293.3
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
1025.0
3065.0
1425.0
#DIV/0!
1160.0
1240.0
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
225.0
160.0
250.0
0.0
95.0
60.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Tooling
Factor
Notes
Alum/RF/300sec/4 Angst/sec
Cu/DC/300sec/10 Angst/sec
Alum/DC/300sec/5 Angst/sec
C1 rotated 20 Deg.
C3 rotated 20 Deg.
DARTMOUTH COLLEGE, #43137
UTILITIES
4.
Utilities
4.1
UTILITIES:
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Utility Requirements
Electrical:
208 VAC (+/- 5 %), 60 Hz, single-phase, 3 wire, 70 Amps.
Water:
(6) GPM, 60-80 °F, 40-60 psig differentials between supply and return (60
psig maximum inlet pressure).
- Water distribution:
1) Cathode #1, #2, and #3, and
2) CTI 8200 water cooled compressor.
3) Open drain for cooling table water exhaust
4) Electric solenoid valve control for “heating and cooling” processes on
substrate table. PC interfaced.
Air:
- Normal dry shop air, 90-110 psi (system valve operation).
- Stand-alone air manifold positioned above the water manifold; solenoid
valves incorporating removable plug-type electrical connections.
i.
Argon (99.9995 % purity):
- 3-15 psi (process gas).
-
Nitrogen (optional):
Preferentially evaporated from a liquid source.
a) 3-15 psi (chamber venting).
-
4.2
SYSTEM GROUNDING PRACTICE FOR RF AND E-BEAM SYSTEMS:
Electrical Grounding:
ii.
iii.
iv.
v.
Ground connection must be made between vacuum system and
building steel.
Denton supplies 25’ of 3” x 0.050” flat copper conductor.
Copper conductor is bolted to vacuum system frame and nearest available
building steel.
Never interrupt the system ground.
4-1
DARTMOUTH COLLEGE, #43137
UTILITIES
4.3
•
•
•
4.4
•
•
•
•
•
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
MECHANICAL REQUIREMENTS:
Commercially purchased components will be new, of industrial quality and demonstrated
"best in class" availability.
All ferrous or aluminum metals will have proper finishes to prevent corrosion or oxidation.
All pneumatic lines, valves, cylinders and flow controls are designed to operate at a minimum
pressure of 90 psi and a maximum pressure of 110 psi.
ELECTRICAL STANDARDS:
The equipment will be compliant to C.E. standards.
All signal power will be isolated from system power; proper shielding and routing practices
must be followed.
All electrical, electronic, and optical sensors must be adequately protected from process
contamination.
Three-phase distribution is 208 VAC, 50/60 cycle (all equipment with three phase inputs
must be supplied for this voltage); single-phase inputs shall be 208 VAC and 120 VAC.
All equipment shall have panelized control with a single entrance protection by a heavy duty
disconnect switch. The disconnect switch will have a "lockout" provision to ensure that no
electrical power can be delivered to the system during maintenance operations.
4-2
DARTMOUTH COLLEGE, #43137
SOFTWARE OVERVIEW
5
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Software Overview
5.1.
Control System
The control system for the vacuum system is GE Cimplicity HMI (Human Machine
Interface). Cimplicity runs on a Windows XP Professional operating system. This should
make the interface between operator and machine familiar and easy to learn.
This software links the operator to the PLC. It allows for data input and data display.
Operators can use a mouse to select on-screen graphics by clicking on any active element
on a screen. Data is input by pushing on-screen buttons or using the keyboard.
Security is implemented through the Login Panel. Multiple levels of security are available
to control access to critical information. The System Administrator has complete access to
the entire control system. The System Operator can access everything except the heat
PID settings, Service Mode and the Configuration Screens in the Recipe Builder. System
Security is described in detail in the System Security section of this manual.
This software is active when power is applied to the system.
Graphic display of the control system is arranged on seven “screens”:
5-1
DARTMOUTH COLLEGE, #43137
SOFTWARE OVERVIEW
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Main Menu (Login)
Overview
Recipe
Alarm View
Main Menu (Login) is the first screen active when power is applied. It gives the
operator access to the other screens through push buttons at the bottom of the screen.
Access to the Login software is through this screen.
Recipe screens are used to develop, store, and download recipes for automated
processes. Recipe screens are fully described in the Recipe Builder section of this manual.
Alarm View is the screen used to display, acknowledge, and clear system alarms. Alarm
View is fully described in the Alarm section of this manual.
Alarm Recovery is the screen that displays the data captured when an automatic
process is interrupted. This information is used to continue a recipe that has been
stopped. Alarm Recovery is fully described in the Alarm section of this manual.
Overview is the primary operating screen. All current system data is displayed on this
screen. The operator can access all subsystems through this screen. The Auto, Manual,
and Service Modes are selected on this screen. Automatic sequences are Started, Stopped
and Reset on this screen. This screen is described in detail in this section of the manual.
This Chapter will describe the Overview screen. An understanding of this screen is
required to proceed with the operation of the vacuum system.
5-2
DARTMOUTH COLLEGE, #43137
SOFTWARE OVERVIEW
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
5.2 Overview Screen
The Overview screen is used to display current system data and provide manual control
of subsystems. The system data and security access level are displayed across the top
and down the left side of the screen. The current state of the vacuum chamber and the
pumping system are graphically displayed in the center of the screen. Subsystem control
boxes are accessible on the right side of the screen. Push buttons across the bottom are
used to switch to Main Menu, Recipe, Alarm View, Alarm Recovery, Open Datalog, PLC
Racks, and Tolerance Alarm screens.
Pushbuttons change color to indicate the state of the switch. Valves, pumps, and
interlocks change color to indicate current state. Graphic indicators are displayed on the
vacuum system graphic when sputter sources, heater, mass flow controllers or bias table
are active.
All operations are familiar Windows operations. All graphics that are accessible to the
operator will display a white “lasso” when the cursor is near the graphic. The valves,
pumps, timers, and individual control boxes are activated by a single click on the mouse.
Data is input into a data box by clicking on the data box, typing in the data, and pressing
the ENTER key.
5-3
DARTMOUTH COLLEGE, #43137
SOFTWARE OVERVIEW
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
5.3 Top Overview Bar
Displays current security data (User ID & Role), mode of operation (MODE), Recipe
name, time of day and date. The User ID and Role are factory set in the control system
software. The current Login name is displayed here. The Mode can be Auto, Manual, or
Service. The mode is selected on the left of the screen.
The current Recipe is displayed at the top of the screen and on the left side of the screen.
The time and date can be adjusted in the Windows Control Panel.
5.4 Left Overview Screen
The left side of the Overview screen is used for System Control, Interlocks, System
Control
5-4
DARTMOUTH COLLEGE, #43137
SOFTWARE OVERVIEW
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
The System pushbuttons at the top select the mode of operation: Auto, Manual, &
Service.
5.4.1
Auto
Auto mode is used to run automatic recipes. The Start, Stop, and Reset buttons are active
in this Mode. The current Recipe Running, Current Step, Sequence Running, and Total
Process Time will advance as the automatic recipe is running.
The Run Number is incremented every time the Start button is pressed. This feature can
be customized to match customer run numbering. Contact Denton Vacuum for more
information.
The Start button starts the Recipe that is displayed. The Stop button stops the recipe at
the end of the current Sequence Running. The Reset button stops the automatic process
immediately and resets the recipe back to the beginning and resets the Total Process
Time.
All buttons change to green when active or ON.
Note: Access to all other on-screen controls is denied in the Auto mode. This
interlock is built in to avoid manual operation of a subsystem in the Auto Mode.
5.4.1.1 Manual
The operator can safely run the system from the Overview screen in
the Manual mode. All interlocks are active in Manual mode. Recipes
are not active in Manual mode.
All on-screen control systems are available. The state of the valves,
motors and fixture rotation can be changed by clicking on the
graphic for that item. Clicking will change the state of simple on/off,
open/closed devices or open control boxes for more sophisticated
controls. The Status & Control boxes on both sides of the screen are
all activated by double-clicking. Pop-up boxes are displayed for
operator input.
The Total Process Time will not advance and the Start and Stop
buttons are inactive in Manual mode. The Reset button is inactive in
the Manual mode.
5.4.1.2 Service
CAUTION: Software Interlocks are inactive in service mode. Caution must
be taken to safely operate the vacuum system
NOTE: Service Mode is not accessible to System Operators. Service Mode
is only accessible to System Administrator. See System Security for
complete details
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SOFTWARE OVERVIEW
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EXPLORER 14 CRYO SYSTEM
Use Service Mode for maintenance. Software interlocks are inactive
in this mode. Hardwired interlocks are active in service mode. All
control systems are active as in Manual mode.
5.4.2
Interlocks
Sputter guns, heater, bias will not operate if any interlock is open. These are
hardwired interlocks.
5.4.3
Auto Deposit Info
Step-by-step information is provided during the deposition of a layer.
“Standby” is displayed at all other times. These messages are intended to
provide the operator with information on the set-up and deposition of a
layer.
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SOFTWARE OVERVIEW
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
5.5 Right Overview Screen
The control boxes for all major subsystems are displayed on the right side of the
Overview screen. The current condition of the subsystems is continuously displayed on
the right side of the Overview screen in data boxes. The subsystems are accessed by
double-clicking on the Status & Control box. A control box will pop-up with input boxes for
operator interface with the subsystem. These are accessed in manual mode.
In normal operation the following data is continuously displayed on the Overview screen:
Sputter Status and Control
RF Bias Status and Control
Heat Status and Control
The individual subsystems are described below. The screens are operated in Manual
Mode only.
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SOFTWARE OVERVIEW
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EXPLORER 14 CRYO SYSTEM
Sputter Status and Control
NOTE: The power supply is interlocked with system vacuum, water , skin switch and
rotation
In this box, the operator can select the desired cathode(s) to use. The System is fitted
with a DC (2) position switch for the single DC power Supply and (1) RF Power Supply.
Therefore, a co-deposition of #1 Cathode using RF and any of the remaining (2)
Cathodes may be used with the DC Power Supply.
After the proper Cathode selection is made, by clicking on the Cathode Select Button
(which will turn Green in color). The operator can set the Power Setting by clicking on the
“window” in the DC or RF supply box. The guns have a Maximum capacity of 600 Watts
for the RF and 2.0 Amps for the DC Power Supply.
To “Turn On” the power supply, Click the On/Off button in that block.
Before Trying to Ignite the gun, you Must First have the Process Gas
flowing!!! This is done on the “Overview Page”
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EXPLORER 14 CRYO SYSTEM
To operate the RF power supply from it’s front panel refer to the RF Power Supply
manuals.
Use the close button to exit the page.
Once the Gun(s) are running, (plasma ignited) you may use this page to open or close
the appropriate shutter for deposition, and start or stop the Substrate Rotation Table.
Overview Page, (lower right hand side) Manual Gas Control
Click on the setpoint boxes and type in the gas flow value, then hit enter. Click on the
desired gas valve to open valve. Next step would be to set the “chamber to pump”
gate valve in the “throttle position”. Do this by clicking on the small box labeled
"Conductance Control" next to the gate valve block. Now you are ready to return
back to the control page to turn on the power supply. Since you are in “manual
mode”, and have a need to raise the chamber pressure higher to ignite the plasma,
(as with RF sometimes) you can simply close the gate valve, lite the gun, and set the
valve to "Throttle" position.
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EXPLORER 14 CRYO SYSTEM
RF Bias Control
Note: The power supply is interlocked with system vacuum, water , skin switch and
rotation
This page allows operation of the Biased Substrate Table. 300 watts should be the normal
upper limit to operate at. To operate, click on the setpoint box and type in power setting,
then hit enter.
To “Turn On” the power supply, Click the On/Off button in that block.
Before Trying to Ignite the gun, you Must First have the Process Gas
flowing!!! This is done on the “Overview Page”
To operate the RF power supply from it’s front panel, refer to the RF Power Supply
manuals.
Use the close button to exit the page.
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EXPLORER 14 CRYO SYSTEM
Substrate Heat Control
This page can be used to operate and monitor a heat process. All the pertinent controls and
system feedback data is present here. The Temperature and Power bar blocks are color
dependent based on system condition and control parameters. Standard PID control loop
technology is also used.
Note: The power supply is interlocked with system vacuum, water , skin switch
and rotation
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SYSTEM OPERATION
6.
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
System Operation
6.1.
System Startup/Cryopump Regeneration, Manual
Warning!
Do not remove the vacuum system skins or defeat the door or skin
switches.
Do not attempt to bypass them.
This is for your safety.
After insuring that all utility connections have been made (See Section 4, Utility
Requirements) the system can be turned on. This system has been fitted with a 8“
cryogenic pump with air-cooled compressor.
Turn ON the main NEMA power breaker and push the green Power switch located on the
door of the computer cabinet ON. The system will power up and the Menu page will be
displayed on the computer screen. The control computer must be ON to successfully
regenerate the cryopump.
6.1.1.
Make sure all valves, pumps, power supplies are OFF or closed. Finish or abort
any automatic sequences that may be running.
6.1.2.
Insure the cryopump purge has the required nitrogen gas supply.
6.1.3.
Insure the chamber is vented.
6.1.4.
Enter the Pumping Control screen.
6.1.5.
Turn off the cryopump.
6.1.6.
Open the cryo purge valve for a minimum of four hours. If the outside of the
cryopump has condensed water or ice on it longer purge times are
recommended.
6.1.7.
Close the cryo purge valve.
6.1.8.
Turn on the mechanical pump.
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6.1.9.
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EXPLORER 14 CRYO SYSTEM
Open the cryo regen valve. Wait until the Cryo TC is below 5.0x10-2 torr.
If the cryo TC pressure, 5.0x10-2 torr, is not achieved in 10 minutes, close the
cryo regen valve and turn off the mechanical pump and return to step 6.1.6. but
only purge for 1 hour.
If the cryo TC pressure, 5.0x10-2 torr is satisfied within 10 minutes proceed with
the following step.
6.1.10. Close the cryo regen valve and turn off the mechanical pump.
6.1.11. Turn on the cryopump if the pressure does not exceed 1.0x10-1 torr in 60 seconds
and proceed to 6.1.12.
If the Cryo TC pressure exceeds 1.0x10-1 torr in 60 seconds return to step 6.1.6.
and purge for only 1 hour.
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6.2
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EXPLORER 14 CRYO SYSTEM
Cryo Pump Regeneration - Automatic Mode
6.2.1
Insure the cryopump purge has the required nitrogen gas supply.
6.2.2
From the Process Display Page select “Recipe” button on bottom tool bar.
6.2.3
Now select the Master Recipe “Edit / Create” button.
6.2.4
From the Master Recipe Page select the “Auto Re-Gen” Recipe and select “open”.
On next screen select “Download”, then “close”. When the Main Recipe page
appears, use the bottom tool bar and select the “overview” page.
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EXPLORER 14 CRYO SYSTEM
6.2.5
Use the return button to go back to the “Process Display “ page.
6.2.6
Start the selected “Cryo Regen” recipe only when you are finished with all
system needs. The system will be in a “holding” mode until the selected date
and time is achieved. No other functions can be performed, unless the
system is aborted.
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SYSTEM OPERATION
6.3
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EXPLORER 14 CRYO SYSTEM
Cryo Pump Regeneration Description - Automatic Mode
6.3.1
Reset required system functions to ready state. This closes all gas and chamber
valves. Turns off all power supplies.
6.3.2
The cryopump is turned off.
6.3.3
The cryo purge valve is opened and flows gas.
6.3.4
The cryo purge valve is closed after the purge or re-purge cycle has been
completed.
6.3.5
The mechanical pump is turned on.
6.3.6
The cryo regen/rough valve is opened. The system waits until the Cryo TC is
below 5.0x10-2 torr. There is also a time delay on some systems that will continue
pumping for another 30 seconds to provide further degassing of the pump array.
If the cryo TC pressure, 5.0x10-2 torr, is not achieved in 10 minutes the cryo
regen valve is closed and the mechanical pump is turned off and it returns to step
6.3.4 and the purge gas will flow for another 30 min. This will repeat for up to 3
times upon failure, before the system aborts automatically.
If the cryo TC pressure, 5.0x10-2 torr is satisfied within 10 minutes it will proceed
with the following step.
6.3.7
With the regen/roughing valve closed, a pressure rise test will take place to
look for the rate of outgassing in the pump. If the pressure does not exceed
1.0x10-1 torr in 60 seconds the “rate of rise” test passes, and continues to
the next step.
6.3.8
If it fails, it will go back to the purge cycle of 30 minutes. This will repeat for
up to 3 times if “rate of rise” tests fail, before the process automatically
aborts.
6.3.9
Upon passing, the cryo regen valve is reopened and the system will pump the
cryo back down to 50 m/t. When the set point is achieved, the cryo compressor
is restarted and the regen/roughing valve will close. Mechanical pump will then
turn off. On some systems, the program allows for continued pumping for up to 2
min.
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EXPLORER 14 CRYO SYSTEM
6.4 Main Chamber Pumping - Automatic Mode
6.4.1
Insure that the Cryo-pump is cold and operational.
6.4.2
From the Master Recipe Page select the “MainPump” Recipe and select “open”.
On next screen select “Download”, then “close” . When the Main Recipe page
appears, use the bottom tool bar and select the “overview” page.
6.4.3
Close the chamber door.
6.4.4
Press the START Auto Sequence button to initialize the automatic pump down
cycle.
6.4.5
The chamber will be in a state of high vacuum when the cycle is complete.
6.4.6
If the chamber door is open it will pause until it is closed.
6.4.7
If the high vacuum valve is open it bypasses the chamber rough phase.
6.4.8
If the high vacuum valve is closed and the Chamber TC SP (below crossover) it
bypasses the chamber rough phase.
6.4.9
If the chamber pressure is above crossover. (150mtorr or 1.5x10-1 torr) the
mechanical pump is started and the chamber rough valve is opened until the
crossover pressure is achieved.
6.4.10
After the crossover is reached the chamber rough valve is closed and the
mechanical pump is turned OFF.
6.4.11
Next the high vacuum valve is opened and after one minute.
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6.5 Main Chamber Pumping - Manual Mode
6.5.1
Insure that the Cryo-pump is cold and operational. This procedure assumes the
chamber is at atmosphere. Make sure all valves, pumps, power supplies are
OFF or closed. Finish or abort any automatic sequences that may be running.
Note: Pushbuttons change color to indicate the state of the switch. Valves, pumps, and
interlocks change color to indicate current state. Graphic indicators are displayed on the
vacuum system graphic when Deposition sources, heaters, shutters, table rotation are
active. All operations are familiar Windows operations. All graphics that are accessible to
the operator will display a white “lasso” when the cursor is near the graphic. The valves,
pumps, timers, and individual control boxes are activated by a single click on the mouse.
6.5.2
Turn the mechanical pump ON.
6.5.3
Close the chamber door and open the chamber rough valve.
6.5.4
Wait until “Chamber TC SP” is satisfied, chamber thermocouple gauge reading
less than 1.5 x 10-1 Torr (crossover pressure).
6.5.5
Close the chamber rough valve and turn OFF the mechanical pump and open the
HiVac valve.
6.5.6
Pressure will be displayed in the FR2 gauge box read-out in the graphic. You will
also note that gauge cross-over setpoints are signified via the green color on the
gauge symbol.
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6.6 Main Chamber Venting - Automatic Mode
6.6.1
This procedure assumes the chamber is in high vacuum. Finish or abort any
automatic sequences that may be running.
6.6.2
From the Master Recipe Page select the “MAIN CHAM VENT” Recipe and select
“open”. On next screen select “Download”, then “close” . When the Main Recipe
page appears, use the bottom tool bar and select the “overview” page.
6.6.3
.WARNING: It is unwise to vent the chamber with the temperature above 200 °C
as the internal components may be adversely effected.
6.6.4
Press the START Auto Sequence button to initialize the automatic chamber vent
cycle.
6.6.5
The chamber will be at atmosphere when the cycle is complete.
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6.7 Main Chamber Venting Description - Automatic Mode
6.7.1
Reset required system functions to ready state. This closes all gas, loadlock, and
chamber valves. Turns off all power supplies and IG gauges.
6.7.2
Pauses vent cycle during the Vent Delay.
6.7.3
Opens the Chamber Vent valve until the chamber door is opened.
6.7.4
The chamber vent valve is also interlocked to a temperature setpoint. The
value is adjustable (with the correct password) by the operator. On the
“Substrate Heat Control” page/screen, the value can be entered from 0 to
200 degrees C.
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EXPLORER 14 CRYO SYSTEM
6.8 Main Chamber Venting - Manual Mode
6.8.1
This procedure assumes the chamber is in high vacuum. Make sure all valves,
pumps, power supplies, and gauges are OFF or closed. Finish or abort any
automatic sequences that may be running.
6.8.2
Wait until the chamber is at a low enough temperature to vent the chamber.
WARNING: It is unwise to vent the chamber with the temperature above 200 °C
as the internal components may be adversely effected.
6.8.3
Close the high vacuum chamber gate valve and Open the vent valve and wait for
the chamber door top open.
6.9 Substrate Heat - Manual Mode
There is no stand alone substrate heat automatic sequence. The substrate is
automatically heated if required in the auto process. However. a heat process alone
can be run.
6.9.1
Insure the chamber is in high vacuum.
6.9.2
Select to the Source button from the Process Display screen.
6.9.3
Turn the substrate rotation power ON if off.
6.9.4
Set the desired substrate temperature setpoint.
6.9.5
Turn the substrate heat power ON.
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6.10
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EXPLORER 14 CRYO SYSTEM
Gas Control for Sputtering- Manual Mode
6.10.1
Insure the chamber is in high vacuum.
6.10.2
Select “gas Control” button from the Process Display screen. Set the desired Gas
flow setpoint(s). Manual operation has the option of a Fixed Flow or PID flow ,
which will require a “pressure set point” to be entered. If multiple gases are to be
used, Master and Slave assignments must be entered also. In the PID mode, the
Master Gas will control the ratio at which the Slave gas set point will flow.
6.10.3 To adjust the Gas correction factors and the mass flow control full range
settings, use the “Gas Names and Setup “ button on the Process Display
Screen.
6.10.4
Open the desired Gas isolation valve(s).
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6.10.5
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EXPLORER 14 CRYO SYSTEM
Select the conductance control valve to be on or off. This is needed only if the RF
Bias or a sputter source is to be used at a pressure that is not suitable for the
cryo pump’s pumping speed when it is not throttled. Adjust the gas flow setpoint
to achieve the desired chamber pressure as measured by the capacitance
manometer when using “fixed flow” mode. Enter a “pressure set point” when
using PID mode.
6.10.6 The “Service Mode” access will get you into this page. Here you can change
the Gun Target material names that show on the process display screen, and
Mass Flow Controller settings. This will allow the operator to swap MFC’s and
re-calibrate the settings to provide accurate software control. Press the
“DOWNLOAD” button after making any changes in settings that the PLC will
use in executing control signals.
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6.11
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RF Bias - Manual Mode
6.11.1 Insure the chamber is in high vacuum.
6.11.2 To operate the bias power, this page will give you all the control that is
needed to start the process. The power supply is interlocked thru the
software, (unless in service mode) to the table rotation. Rotation must be
on. The other step that must be taken, is that the MFC flow setting must be
entered on the Process Display Page , in “manual” mode. The “manual” RF
Bias Source Control page only works in “FIXED FLOW” , so do not try to use
the other ‘Gas Control” page for setting flow setpoints.
6.11.3 Select the conductance control valve to be on or off. This is needed only if
the RF Bias or a sputter source is to be used at a pressure that is not suitable
for the cryo pump’s pumping speed when it is not throttled.
6.11.4 Close the High Vac valve if a pressure rise is need to ignite the plasma.
Usually the RF plasma lights easily above 20 m/t . After ignition, re-open the
valve.
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6.12 Sputtering - Manual Mode
6.12.1
Insure the chamber is in high vacuum and a gas flow gas flow set points have
been established on the Process Display Page.
6.12.2 Turn on gas flow and Select the conductance control valve to be on or off.
This is needed only if the RF Bias or a sputter source is to be used at a
pressure that is not suitable for the cryo pump’s pumping speed when it is
not throttled. Turn the substrate rotation power ON if off for interlock
setting.
6.12.2
Select to the SOUCES by using the “Select” buttons on the Sputter Control
screen.
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EXPLORER 14 CRYO SYSTEM
6.12.4
Set the desired DC / RF setpoint for the required cathode/s.
6.12.5
Turn ON the required power supply now for DC cathodes.
6.12.6 Close the High Vac valve if a pressure rise is need to ignite a plasma. Usually
the RF plasma lights easily above 60 m/t . Turn on the power supply. After
ignition, re-open the High Vac valve.
6.13 Auto Sputter - Automatic Mode
6.13.1
Program the Auto Sputter sequence. Start by opening the Recipe Page.
And select the Deposition T – Step file by clicking the edit / create button.
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6.13.2
From this page, begin by selecting the OPEN or NEW buttons in the upper left
hand corner of the page. Either select an existing recipe or create a new one.
6.13.3
To create a new process, you only need to follow a couple guidelines.
6.13.4
(1) Each column is a TIME SEGMENT of the process. The entry on the 1st line
(top) in each column sets the duration of that step. Certain functions will delay
the countdown of this timer however! These are: system waiting to achieve
minimum vacuum level (line # 2), Heat Temp setpoint (line # 3), Ignition
pressure setpoint (line # 24).
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6.13.5
(2) The gas control mode must be selected when using the MFC’s, (light green
line). When in fixed mode , you need not input a gas PID pressure setpoint, (pink
line). When PID mode is selected, (light green line), you must input MASTER or
SLAVE. These inputs are selected via a “drop down” box which requires a mouse
click in the box. If you are using multiple MFC’s, you must also assign MASTER or
SLAVE. Only one gas can be MASTER. When using a MFC in the PID mode, you
must enter a setting in the GAS SET POINT row. When using only GAS 1, you
must only assign any numeric value, (1, or 5, or 3, or 11, etc). This tells the MFC
to open, then it will go to the flow needed to meet the pressure setpoint entered
in the PINK row. If you are using multiple MFC’s, the numeric value is more
significant. The values that you enter will set up the GAS RATIO between the
multiple MFC’s.
6.13.6
(3) The rotation speed must always be entered, (yellow line) if you want
continuous substrate rotation.
6.13.7
(4) The CONDUCTANCE CONTROL valve, (light blue line) must be entered for all
steps if required. This box also has a “drop down” feature to offer a selection.
6.13.8
(5) You cannot change the gun selection, (purple color box), while a gun is in
operation, (if a setpoint has been entered “pre-sputter” or “sputter” watts). You
must turn-off in one T-Step, and switch in the next T-Step, then turn-on the
selected gun.
6.13.9
(6) When running a gun, the SELECTION line, (purple rows), must have an
entry.
6.13.10 (7) To signify the end of the process, you must use the last row, END PROCESS
(YES). In this T-Step, you must enter a time, (line # 1) of at least 5 seconds.
6.13.11 With these guidelines in mind, you will be able to program all desired functions
for heat , etching , depositions with and without bias multiple gas flow and
control modes, and multiple cathode selections / usages. Film thicknesses are
controlled via the power settings and the length of time (sum of T-Steps) in
which the gun has a power entry.
6.13.12 To save a recipe, simply click the SAVE button, assign a name and click OK. Then
click the close button to go back to the MASTER RECIPE page.
6.13.12.1 To create a new recipe from an existing one, use the OPEN
button and click on a recipe to highlight it and use the OPEN button
on that page. The spread sheet will populate the data boxes with
the stored information in that file. You may edit the values and the
T-Step commands to suit.
6.13.12.2 Using the COLUMN buttons you can insert steps as needed or
delete steps Once the appropriate changes are made, click on the
SAVE AS button, edit the recipe name for a new one, and ENTER.
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6.13.12.3
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The new recipe name will show in the file box now. Click the
CLOSE button to bring you back to the MASTER RECIPE screen.
6.13.13 Once you have assigned a name and saved it, the recipe will be downloaded to
the MASTER RECIPE FILE. It can now be retrieved in that page, by clicking on
the EDIT/CREATE button.
6.13.14 Under the “SEQUENCE TYPE” drop – down menu of “Depositions”, highlight
and click. Then , scroll thru the SEQUENCE LIBRARY to find it.
Scroll thru the recipes that are listed in the “USER DEFINED SEQUENCES”
drop – down box until you see the one you just created.
To BUILD a complete process to run you must chose the items you wish in
the correct sequence you wish to have them executed. Use the steps listed
in the “User Defined” box to build the “MASTER Sequence List”. Highlight the
defined sequence and the click the ADD button. This will move the item onto
the MASTER list. The INSERT and REPLACE buttons are convenient tools for
editing recipes or steps.
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In the SEQUENCE TYPE box, you will find all the standard operations and categories
for the “libraries of recipes”.
STANDARD OPERATIONS
These standard operations are used for Pumping the Load Lock down, Loading and
Unloading the substrates after the T-Step process runs are done, and then Venting
the Load Lock for substrate removal.
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EXPLORER 14 CRYO SYSTEM
LIBRARIES OF RECIPES
(user defined sequences)
6.13.15
Once you have loaded all the required steps in the MASTER SEQUENCE LIST
area, you must click the “Save As button” . This will bring up the MASTER RECIPE
screen. Type in a name, and click SAVE.
6.13.16
If you want to run an existing recipe, just click the OPEN button on the
MASTER RECIPE BUILDER page.
6.13.17
Highlight the desired recipe on the OPEN MASTER RECIPE screen and click
OPEN . This will download the file back to the previous screen, where all the steps
can be reviewed.
6-20
DARTMOUTH COLLEGE, #43137
SYSTEM OPERATION
6.13.18
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Now that you have named and saved your new recipe, or have selected an
existing recipe, and it is loaded in the MASTER SEQUENCE LIST box on the MASTER
RECIPE BUILDER page, just click the DOWNLOAD button, o load it in the main
RECIPE page. The recipe’s name will appear in the ACTIVE RECIPE block. It will also
now appear on the system overview screen in the RECIPE NAME block , (upper left
hand corner), located in the SYSTEM CONTROL zone.
6-21
DARTMOUTH COLLEGE, #43137
SYSTEM OPERATION
6.13.19
6.13.20
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
Press the START Auto Sequence button to initialize the Auto deposition process.
The automatic process selected will be executed. When the T – Step portion of
the process begins, the recipe steps will be displayed next to the “System Control”
zone.
6-22
DARTMOUTH COLLEGE, #43137
SYSTEM OPERATION
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
6.14 Auto Sputter Description - Automatic Mode
The AutoSputter process sequence is capable of all of the system functions required
to sputter multi-layer, with or without substrate heat, with or without RF Pre-clean.
6.14.1 The system has options that can be used during the Auto Process Runs.
These selections can be made during the run and are located in the SYSTEM
CONTROL zone on the overview page.
6.14.2 The ABORT button will stop the system in a safe state. All power supplies
and gas sources will be turned off. The system will leave the high vacuum
valve open and continue to maintain the vacuum operation. Using the
ABORT button will require MANUAL intervention, for re positioning the
substrate or manipulation mechanisms.
6.14.3 HOLD AT END OF SUBROUTINE button, will pause the system after auto
processes that do not take place in the T – Step recipes. For example, Heat
6-23
DARTMOUTH COLLEGE, #43137
SYSTEM OPERATION
DENTON VACUUM, LLC
EXPLORER 14 CRYO SYSTEM
and Etch subroutines. A new recipe will have to be run to continue on, if this
is selected, or use the MANUAL mode to continue processing.
6.14.4 The RECIPE MANUAL ACCESS button can be used during the T – Step
processes. It allows you to change the values in that step via the MANUAL
control screens for the power supplies and gas flow controllers. At the end of
that step, the recipe values in the next T- Step will be re-entered.
6-24
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
7.
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
System Alarms
Purpose: The purpose of this section is to outline the manual steps required to correct an
alarm condition in a Explorer 14 vacuum system.
7.1 Programmable Tolerance Alarms:
Process Pro has the ability for the User to set several programmable tolerance alarms.
These alarms, by the use of a slider bar, can be varied to meet tighter or wider tolerances
for the specific process. These alarms are always enabled regardless of mode of
operation.
7-1
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
The alarm can be varied by using the mouse and moving the Slider Bar to the desired
level or the value of the slider can be varied by clicking the Value and entering the value
by the use of the keypad. The Process Kill pushbutton, when set, will be a red blinking
button that will end an automatic process upon the set of the alarm. When first set, the
alarm will appear on the Alarm View with text describing the alarm and will be blinking
Red.
When acknowledged from the operator, the alarm will be blinking yellow. These Alarms
are considered HIGH alarms and will be the only alarms blinking.
7-2
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
The following list contains Programmable Tolerance Alarms for operation and a brief
explanation of the alarm message.
Alarm Message
Explanation
Recommended Action
RF #1 P.S. SPUTTER
SETPOINT!! OUT OF
TOLERANCE #1002
RF sputter power supply setpoint is
out the programmed tolerance.
The tolerance is the percentage (%)
above and below the setpoint
Make sure the chamber is at the
required pressure (above 2
mtorr). The RF Bias may
require higher pressure to
ignite. Close the high vacuum
bypass valve until the cathode
ignites. Typically 8-12 mtorr is
sufficient
RF1 SPUTTER
REFLECTED POWER!!
OUT OF TOLERANCE
#1003
RF sputter programmed Reflected
Power tolerance point has been
exceeded.
DC #1 P.S. SPUTTER #2
OR #3 SETPOINT!! OUT
OF TOLERANCE #1004
DC sputter power supply #1
setpoint is out the programmed
tolerance. The tolerance is the
percentage (%) above and below
the setpoint
DC #2 P.S. SPUTTER #4
SETPOINT!! OUT OF
TOLERANCE #1005
DC sputter power supply #2
setpoint is out the programmed
tolerance. The tolerance is the
percentage (%) above and below
the setpoint
RF #2 P.S. BIAS
SETPOINT!! OUT OF
TOLERANCE #1006
RF Bias power supply setpoint is out
the programmed tolerance. The
tolerance is the percentage (%)
above and below the setpoint
RF2 BIAS REFLECTED
POWER!! OUT OF
TOLERANCE #1007
RF Bias programmed Reflected
Power tolerance point has been
exceeded.
BIAS VOLTAGE OUT OF
TOLERANCE #1008
RF Bias Voltage programmed
tolerance point has been exceeded.
VACUUM ALARM!! MIN.
VACUUM SETPOINT
TIMEOUT #1009
During an Auto Process the
minimum vacuum setpoint has not
been reached within the
programmed time limit.
7-3
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Alarm Message
Explanation
Recommended Action
AUTO HEAT ALARM –
TEMPERATURE
SETPOINT TIMEOUT!!
#1010
During an Auto Heat Process the
heat setpoint was not reached
within the programmed time limit
HEAT ALARM –
SETPOINT TOLERANCE
LIMIT!! #1011
The heat setpoint is out the
programmed tolerance. The
tolerance is the percentage (%)
above and below the setpoint
HEAT ALARM!! DANGER!!
OVERTEMP ALARM
#1012
The actual heat temperature in the
main chamber has exceeded the
programmed setpoint. The
temperature in the chamber is
dangerously high.
TRANSFER TEMP TOO
HIGH!! #1013
The main chamber temperature is
too HOT for transfer in or out
GAS #1 SETPOINT OUT
OF TOLERANCE!!! #1014
Gas #1 setpoint is out the
programmed tolerance. The
tolerance is the percentage (%)
above and below the setpoint
GAS #2 SETPOINT OUT
OF TOLERANCE!!! #1015
Gas #2 setpoint is out the
programmed tolerance. The
tolerance is the percentage (%)
above and below the setpoint
TOLERANCE ALARM
PROCESS KILL!! #1017
NON-Programmable Alarm. Informs
operator that a Programmable
Alarm HAS ended a Automatic
Process.
N/A
CAUTION!! SYSTEM IN
SERVICE MODE #1018
NON-Programmable Alarm. Informs
operator that system is now in a
non-interlocked Service Mode.
Qualified personnel only!!
Service Mode for Qualified
personnel only!!
7-4
Tune PID
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
The following list contains Alarms for system operation and a brief explanation of the
alarm message. These alarms are considered MEDIUM Alarms and will be a steady
Red until acknowledged, when they turn to a steady Yellow. These MED alarms
consist of system interlocks, equipment interlocks and system operation.
Alarm Message
Explanation
Recommended Action
AUTO PROCESS
COMPLETE!! #2001
Automatic process has ended.
No action required.
WARNING!! AUTO
PROCESS WAS ABORTED
#2002
Automatic process has ended
because the STOP button was
depressed.
No action required.
RF BIAS INTERLOCK
ALARM!! DOOR OPEN!!
#2003
The main chamber door is open and
the BIAS Power Supply was initiated
either manually or by an automatic
process
Check door sensor. The
hardware sensor, if satisfied and
working, has an LED that
illuminates when satisfied.
RF BIAS INTERLOCK
ALARM!! NO ROTATION!!
#2004
The main chamber rotation is NOT
on and the BIAS Power Supply was
initiated either manually or by an
automatic process
Check rotation.
RF BIAS INTERLOCK
ALARM!! NO VACUUM!!
#2005
The main chamber vacuum is not
set and the BIAS Power Supply was
initiated either manually or by an
automatic process
Check vacuum switch
RF BIAS INTERLOCK
ALARM!! NO WATER!!
#2006
The BIAS water sensor is not set
and the BIAS Power Supply was
initiated either manually or by an
automatic process
Check water switch
Cathode #1 Water Not
Satisfied #2008
Cathode #1 water was lost while
the power to the cathode or the
Heat was on.
Check water switch
Cathode #2 Water Not
Satisfied #2009
Cathode #2 water was lost while
the power to the cathode or the
Heat was on.
Check water switch
Cathode #3 Water Not
Satisfied #2010
Cathode #3 water was lost while
the power to the cathode or the
Heat was on.
Check water switch
7-5
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Alarm Message
Explanation
Recommended Action
DC 1 SPUTTER
INTERLOCK ALARM!!
DOOR OPEN!! #2012
The main chamber door is open
and the DC #1 Power Supply was
initiated either manually or by an
automatic process.
Push door closed.
DC 1 SPUTTER
INTERLOCK ALARM!! NO
ROTATION!! #2013
The main chamber rotation is NOT
on and the DC #1 Power Supply
was initiated either manually or by
an automatic process.
Push door closed.
DC 1 SPUTTER
INTERLOCK ALARM!! NO
VACUUM!! #2014
The main chamber vacuum is not
set and DC #1 Power Supply was
initiated either manually or by an
automatic process
Check vacuum switch
DC 1 SPUTTER
INTERLOCK ALARM!! NO
WATER!! #2015
The DC #1 water sensor is not set
and the DC #1 Power Supply was
initiated either manually or by an
automatic process
Check water switch
HEAT INTERLOCK
ALARM!! NO ROTATION!!
#2020
The Heat was initiated by a manual
PB or a auto process and there was
no rotation on.
Turn rotation on. Check fuses.
HEAT INTERLOCK
ALARM!! NO VACUUM!!
#2021
The Heat was initiated either
manually or by an automatic
process and the vacuum switch is
not set.
Check vacuum switch.
7-6
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Alarm Message
Explanation
Recommended Action
HIVAC VALVE ALARM!!
ROUGH VALVE OPEN
INITIATED #2022
The hivac valve is open and either
the rough pb was initated or an
auto process called for the rough
valve open.
No Action
VENT VALVE ALARM!!
ROUGH VALVE OPEN
INITIATED #2023
The hivac valve is open and either
the vent pb was initated or an auto
process called for the vent valve
open.
RF SPUTTER INTERLOCK
ALARM!! DOOR OPEN!!
#2026
The main chamber door is open and
the RF Power Supply was initiated
either manually or by an automatic
process
RF SPUTTER INTERLOCK
ALARM!! NO
ROTATION!! #2027
The main chamber rotation is NOT
on and the RF Power Supply was
initiated either manually or by an
automatic process.
Push door closed.
RF SPUTTER INTERLOCK
ALARM!! NO VACUUM!!
#2028
The main chamber vacuum is not
set and RF Power Supply was
initiated either manually or by an
automatic process
Check vacuum switch
RF SPUTTER INTERLOCK
ALARM!! NO WATER!!
#2029
The RF Sputter water sensor is not
set and the RF Power Supply was
initiated either manually or by an
automatic process
Check water switch
7-7
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
Alarm Message
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Explanation
REGEN
ALARM!!
setpoint Failure!!
Recommended Action
3RD Cryopump has been purged and
pumped three times and has not
made minimum vacuum setpoint.
Auto Regen program stops after
third failure.
REGEN ALARM!! RATE OF Cryo-pump will not hold vacuum
RISE TEST FAIL!!
setpoint for one minute.
REGEN ALARM!! 20 MIN Cryo-pump has not made minimum
PURGE CYCLE START!!
vacuum setpoint. Failed after first or
second purge & pump cycle.
AUTO PUMP
CROSSOVER
TIMEOUT!!
ALARM - Crossover setpoint not reached in
SETPOINT preset amount of time.
Check for possible cause (i.e.
leak). Check mechanical pump.
Correct and proceed.
AUTO PUMP ALARM - Process pressure setpoint not Check for possible cause (i.e.
PROCESS
PRESSURE reached in preset amount of time.
leak). Check cryopump. Correct
SETPOINT TIMEOUT!!
and proceed.
The following list contains Cimplicity software alarm messages as they appear on the
Alarm Screen and a brief explanation of the alarm message. (%s indicates the name of a
point in the system database.)
NOTE: Some alarms are built into the software and are used to control the
transfer of information into and out of a database. Others are built into the
software to handle network control. These alarms require little or no action on
the part of the operator.
7-8
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM ALARMS
Alarm Message
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Explanation
Recommended Action
Logging failure on database Failure of data logging into the Acknowledge, Delete & Ignore
table %s
database: internal alarm
Comm error or dynamic disable, XTC/2 Deposition Controller is Reboot the system.
device %s
not communicating with system.
Failing over to redundant device Device Failover alarm for PLC Acknowledge, Delete & Ignore
%s
redundancy.
Log file almost full
Network alarm.
Acknowledge, Delete & Ignore
User ID %s disabled, computer User disabled due to bad login.
%s
Acknowledge, Delete & Ignore
User %s Logged ON
Network alarm.
Acknowledge, Delete & Ignore
User %s Logged Out
Network alarm.
Acknowledge, Delete & Ignore
%s of the redundant pair is Alarm for PLC redundancy.
down
Acknowledge, Delete & Ignore
The process %s has lost its Database connection failed.
database connection to %s
Reboot the system.
The process %s has begun to Database communication error.
forward data to %s
Reboot the system.
Process %s Terminated on %s Process terminated
Process name %s
unexpectedly.
Reboot the system.
7-9
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM INTERLOCKS
8.
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
System Interlocks
The following interlocks are active in manual and automatic modes. The operation of the
following functions will be blocked without satisfying its interlocks. Interlock messages
are given alerting the operator as to the reason for the limitation.
The below software interlocks can be defeated by enabling the Service Mode. CAUTION:
ONLY Maintenance Level access can enable the Service Mode. The Service Mode control
is found in the Maintenance screen.
Device
Limitation
Reason
Mechanical Pump
Can’t turn ON or OFF if
Chamber rough is open
LL rough is open
Cryo Pump
Can’t turn ON or OFF if
Cryo regen is open
Cryo purge is open
Cryo pressure above 100mtorr
Chamber Rough valve
Can’t open if
Chamber door is open
Mech. Pump is off
Hivac valve is open
Chamber vent valve is open
LL rough valve is open
To Close
No Interlocks.
Can’t open if
Chamber pressure above
150mtorr
Chamber door is open
Chamber vent valve is open
Chamber rough valve is open
Cryo pump is off
To Close
No Interlocks.
Can’t open if
Chamber door is open
Chamber rough valve is open
Chamber hivac valve is open
Heat power is on
Any Sputter power on
RF Bias power is on
To Close
No Interlocks.
Chamber Hivac valve
Chamber Vent valve
8-1
DARTMOUTH COLLEGE, JOB # 43137
SYSTEM INTERLOCKS
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Device
Cryo Purge valve
Cryo Regen valve
Limitation
Reason
Can’t open if
Cryo pump is on
Cryo regen valve is open
To Close
No Interlocks.
Can’t open if
Cryo pump is on
Cryo purge valve is open
To Close
No Interlocks.
Gas Valves
No interlocks
Sputter Power 1-4, RF Bias power
Can’t be turned on if
Skin switch not satisfied
Bellows switch not satisfied
Chamber door open
Water switch not satisfied
To Turn OFF
Can’t turn on if
No Interlocks.
Skin switch not satisfied
Bellows switch not satisfied
Chamber door open
Any water switches not satisfied
To Turn OFF
No Interlocks.
Heat Power
8-2
DARTMOUTH COLLEGE JOB # 43137
SYSTEM MAINTENANCE
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
9. System Maintenance
9.1
ProcessPro Total Solution Server
DVI Service using MS Terminal Service
MS Internet Explorer and creating a private network between DVI and customer
for up to the minute options of DVI Service
Real Time Process evaluation and diagnostics
Remote monitoring for needed periodic access to system information for a
higher level of support
Support person has the ability to diagnose and resolve configuration problems,
as well as online training
High performance Ethernet Modem located anywhere (wireless)
Better service connectivity creates a better dialogue between customer and
manufacturer using a direct connection.
DVI Service can receive emails from alarms, view reports, diagnose computer
system resources
Calendar based control operations for Preventive Maintenance
Security Authorization
Allow only authorized Users, including DVI Service, to view secured areas or
data
Interactive access for several users for read-only viewing
Report Manager / Data Reporter
Built-in scheduler allows unattended reporting
Schedule periodically, daily, weekly, monthly reports
Maintain an internal database for
Standard deviation from run to run
SPC
Collect, measure, analyze and warn of possible
quality control problems
Process related reports
Display multiple reports for simultaneous for accurate comparison
Available through Intranet and/or email via dedicated phone line to DVI
Use MS SQL V7.0 for data logging applications
Integration becomes easier into existing networks
Computer System Sentry
Superior monitoring of the computer system
Monitors and records parameters and statistics like alarm
frequency, device communications, data collection and
throughput and user registration.
Monitors critical operating system and network information, such
as CPU performance, memory consumption, and process time,
to give you a complete and current status of your system's
health.
“Open” (OPC) software architecture
Easy integration of plug and play interface with individual or 3rd party software
OPC is an emerging standard to provide interoperability between software,
hardware systems and devices.
9-1
DARTMOUTH COLLEGE JOB # 43137
SYSTEM MAINTENANCE
9.2
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Chamber Cleaning
1. Change shields when coating begins to flake off the metal.
2. Partial shield changes can be made when required.
3. All shields must be cleaned using a beadblaster to remove built-up coating. Care
must be taken to prevent contact with oils or grease.
4. After cleaning in a beadblaster, the shields must be wiped down with isopropyl
alcohol or acetone before being reinstalled.
5. Any exposed chamber areas must be scrubbed with Scotchbrite and wiped with
isopropyl alcohol or acetone.
9.3
Mechanical Pump
1. Check oil level daily. Do this when pump is not operating.
2. Check the color of the oil monthly. Compare it with a sample of new oil. If the oil is
brown, black or smell “burnt”, it has deteriorated. Drain the pump and change the
oil.
3. See the Troubleshooting section of the subsystem operating manual.
9.4
Cryogenic Pump
1. Check the temperature gauge daily. A reading above 20K indicates the pump
requires regeneration.
2. Check and record the operating pressures monthly.
3. Replace the seals and inspect the valve stems at 10,000 hours of operation.
4.
Replace the adsorber unit at 30,000 hours of operation.
5. See the Troubleshooting section of the subsystem operating manual for specific
instructions.
9.5
High Vacuum Valve
1. Check main o-ring seal annually. This requires disassembly of the valve. Replace oring seal if it is scored or brittle.
9-2
DARTMOUTH COLLEGE JOB # 43137
SYSTEM MAINTENANCE
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
9.6 Rotary Feedthroughs
1. Fixture Drive and Shutter Drive should be disassembled and inspected every 6 - 12
months.
2. Replace all damaged, brittle, or worn seals. Clean and lubricate all seals before
reassembly.
9.7
Overall System Maintenance
1.
9.8
Refer to instrument manuals.
Fuse Ratings
FU-3
RATING
ALL FUSES ARE
SLOW-BLOW
2 Amps
FU-4
2 Amps
FU-5
5 Amps
FU-6
FU-7
2 Amps
0.5 Amps
FU-8
0.5 Amps
FU-9
0.25 Amps
FU-10
FU-11
FU-15
FU-15A
FU-16
FU-17
FU-18
FU-19
FU-20
FU-21
FU-25
FU-26
FU-28
FU-40
10 Amps
10 Amps
1 Amps
1 Amps
10 Amps
10 Amps
20 Amps
20 Amps
15 Amps
15 Amps
10 Amps
10 Amps
2 Amps
1 Amps
FU-41
FU-46
2 Amps
1 Amps
FUSE
9-3
CIRCUIT
24 VDC Power Supply
Primary
24 VDC Power Supply
Primary
24 VDC Power Supply
Primary
Auxiliary Power (Rec 1)
Signal Transformer-T1
Primary
Signal Transformer-T1
Primary
Signal Transformer-T1
Secondary
Heat Power
Heat Power
Rotation Control
Rotation Control
Mechanical Pump
Mechanical Pump
Cryo Pump CTI 8
Cryo Pump CTI 8
DC 1 Power
DC 1 Power
RF 1 Power
RF 1 Power
PLC Power
12 VDC Power Supply
Primary
Cryo Heater Blanket
± 15 VDC Power Supply Primary
DARTMOUTH COLLEGE JOB # 43137
SYSTEM MAINTENANCE
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
FUSE
RATING
ALL FUSES ARE
SLOW-BLOW
CIRCUIT
FU-47
1 Amps
FU-48
FU-49
FU-50
5 Amps
5 Amps
0.5 Amps
± 15 VDC Power Supply
Primary
RF 2 Power
RF 2 Power
Capacitance Manometer
9-4
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
10.
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Troubleshooting
10.1
Safety Warnings:
WARNING!
DUE
TO THE NATURE OF THE SUBSYSTEMS, THERE ARE MANY TYPES OF VOLTAGES ON A VACUUM
SYSTEM. LETHAL HIGH VOLTAGES ARE PRESENT!
READ
THE OPERATING MANUALS SUPPLIED WITH THE SYSTEM BEFORE ATTEMTING ANY TYPE OF
TROUBLESHOOTING ON THE VACUUM SYSTEM. REFER TO THE PROPER SECTIONS OF THE OPERATING
MANUALS TO VERIFY THAT THE SYSTEM IS BEING OPERATED IN THE PROPER MANNER.
INTERLOCKS ARE BUILT IN TO THE CONTROL SYSTEM. RATHER THAN ASSUMING A SYSTEM
VERIFY THE PROBLEM IS NOT AN INTERLOCK INTENDED TO PREVENT UNSAFE OPERATION.
NOTE ON JEWELRY
WHEN WORKING AROUND A VACUUM SYSTEM, THERE IS ONE GOOD PRACTICE:
DO NOT WEAR JEWELRY!
AN ARC MAY BE DRAWN FROM A HIGH VOLTAGE SOURCE!
10-1
FAILURE,
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
10.2
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Required Tools:
Tool
Use
Multimeter
A. To read AC or DC Voltages
(Analog or Digital)
B. To read low AC or DC Current
C. To read resistance (Ohms)
Hand-held Current Meter
Clamps around an AC line read current.
(Amp Probe)
Screwdrivers
For disassembly and assembly.
(Flat & Phillips)
Wrenches
For disassembly and assembly: 3/8” to 1”
(Box Type)
Allen Wrenches
For disassembly and assembly: 1/16” to 3/8”
10-2
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
10.3
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Vacuum System Control Rack:
Problem:
No activation of subsystems when main switch is toggled.
Cause:
No +24V DC power from DC power supply.
Solution:
1) Check to see if there is 208V AC, 3 phase power at main breaker of vacuum
system.
2) Turn ON main breaker.
3) Turn ON aux. breaker.
4) Press green “START” button.
5) Check the fuse F2 for the 24 volt DC supply located in the NEMA enclosure.
Replace if blown.
6) Check the fuse F1 for the AC power to the DC power supply located in the NEMA
enclosure. Replace if blown.
7) Pull out 24 volt fuse from panel. Then with voltmeter, check output terminals of
the +24 volts at power supply. These terminals can be found on the 24 volt
supply P.C. board.
8) Check AC input on transformer of DC power supply to see if 120V AC is present
9) If there is 120V AC input power, but no 24V DC output, replace the power
supply.
10) If there is no AC power at this point, call Denton Vacuum (856-439-9100).
Problem:
Subsystems activated, but no control of pumps, valves and subsystems.
Cause:
24V Relays.
Solutions:
1) Be sure all relevant interlocks are satisfied before proceeding.
2) Pumps, valves and subsystems are controlled through the PLC by relays. Each
relay is numbered. Identify the correct relay according to the schematic and
check correct position (OPEN/CLOSED) of the relay. Visually verify the proper
operation of the relay against the schematic.
3) If the relay fails to operate, remove it and use an Ohm meter to read the
resistance of the coil. Verify that the coil is not shorted.
4) Verify that the contacts are not fused and preventing movement.
10-3
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
5) If there is a problem with a relay, replace it.
6) Use a volt meter to determine if a signal is going to the relay.
7) If the relay is not receiving a signal to open or close, contact Denton Vacuum
(856-439-9100).
10.4
Valves and Shutters:
The source shutter and all vacuum valves on the vacuum system are pneumatically
controlled. The valve opening procedure is as follows:
There is a 24V DC signal from an output relay that feeds into a DC solenoid
(electromagnetic) coil. The electromagnetic field created by the coil pulls up a “plunger
valve” mounted to the air flow manifold. When this “plunger” is pulled up it permits air
pressure (80 - 100 psi) to pass through the manifold into an air operated cylinder. The air
pressure going into the air cylinder becomes greater on one side than the other. The side
of the cylinder with the greater air pressure will move a “diaphragm” the opposite way.
Depending on which way the diaphragm is traveling the valve is opened or closed.
When the assigned output is activated, the valve or shutter associated with it
does not respond. The on-screen indicator changes state.
Problem:
Causes:
A. No air pressure to the air manifold.
B. No power at the valve or shutter solenoid.
C. Valve or shutter solenoid defective.
Quick Test: Before going on to the solutions for the above causes, there is a
quick way to verify that a solenoid valve has +24V DC and the solenoid is
active:
Place a common metal screwdriver on top of the solenoid with the valve output
ON. If the screwdriver is slightly magnetized to the top of the solenoid, the coil
is good and there is most likely a mechanical problem such as no air or a stuck
plunger. Remember this is only a quick test. It is not 100% fool-proof.
Solutions (Cause A):
1) Verify that there is 90 - 100 psi of air pressure to the vacuum system. Inspect air
lines and filter for water.
2) Prove that there is air to the valve in question.
Each valve has two air lines attached to it: one for air in and one for return.
These air lines are attached by special fittings that make it easy to detach or
reattach an air line. These fittings are called “LEGRIS” fittings.
10-4
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
While holding one of the air lines firmly in your hand, push in the red collar
on the Legris fitting, pull out air line while pushing the red collar of the Legris
fitting inward.
NOTE: There might be 90 - 100 psi of air pressure in the line. Make
sure that you have a firm grip on it so it does not “whip” out of
your hand.
While holding air line, activate and deactivate power to the solenoid.
Air should flow out of the Legris fitting mounted in the air manifold when
power is at one state (ON/OFF), and air should stop flowing when the power
to the solenoid is in the other state (ON/OFF).
Repeat steps 2 through 5 for second air line to see if it operates the same
way.
If both Legris fittings operate with alternating air ON/OFF, the problem is
internal to the valve assembly.
Disassemble valve in question and inspect for foreign matter or broken seals.
3) If the air flow from the Legris fitting did not change from one port to the other or
when switched ON/OFF, then follow Solutions (Cause #2) below.
Solutions (Cause B):
1) Locate the solenoid valve attached to the air manifold.
2) Open the black plastic enclosure that holds the wires connecting to the solenoid.
3) When the wires have been located, expose the connectors that join the signal
wires to the solenoid.
4) Place a voltmeter across the wires at the crimp connectors.
5) Disconnect the solenoid from the output leads and try to read +24V DC power at
the ends of the two wires.
6) If there is NO power at the solenoid when the output is high, use the system
schematic and a voltmeter, trace the signal lines and inspect for breaks.
7) If there IS power on the signal lines when disconnected from the solenoid and
the solenoid is not operating, see Solutions (Cause C).
Solutions (Cause C):
1) Disconnect solenoid from signal leads.
2) Use an Ohm meter to read the resistance of the solenoid.
3) A reading of approximately 65 - 85 Ohms (+/- 10%) indicates a good solenoid.
4) A reading of 00.0 Ohms indicates a shorted solenoid.
10-5
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
5) Replace the solenoid, then try the valve.
6) A reading of infinity indicates the solenoid is burnt out (open coil).
7) Replace the solenoid, then try the valve.
10.5
Rotation:
Problem: When rotation is powered ON it does not rotate, or it stops rotating in the
middle of a run
Causes:
A. Fuse blown.
B. Power to and/or from the motor controller is not active.
C. Rotation is mechanically jammed.
Solutions (Cause A):
1) Locate B&B Nova Motor Controller in the control rack. Read the subsystem
operating manual to become familiar with the Nova Controller.
2) Shut power to the Motor Controller OFF before proceeding.
3) At the rear of the Motor Controller under the P.C. board locate the fuse holder
and 8 Amp fuse.
4) Remove the fuse and check it with an ohm meter. If blown, replace.
5) Examine the traces on the P.C. board around the fuse holder. If they are burnt,
replace the Nova controller.
Solutions (Cause B):
1) Use a voltmeter to measure the 120 VAC power going into the Nova controller on
the terminals “L-1” and “L-2”.
2) If NO power is present, use the use the system schematic and a voltmeter, trace
the signal lines and inspect for breaks.
3) If there IS power coming in to the controller, then the DC output power from the
controller must be checked for both the field and armature.
4) Disconnect the four motor wires from the terminals marked “A1, A2, F1, &F2”.
5) Set the volt meter to DC Volts and read the output power on terminals “F1 & F2”
(field). There should be a constant voltage of 135 VDC no matter where the
control pot is set.
10-6
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
6) Set the volt meter to DC Volts and read the output power on terminals “A1 & A2”
(armature). Take readings while adjusting the control pot from zero to full scale.
The output should vary from zero to 100% output as the control pot is varied.
Full power should be 120 VDC to 135 VDC.
7) If either or both DC outputs are disabled for the field or armature, replace the
motor controller.
Solutions (Cause C):
1) Inspect main bearings in the planetary drive for damage.
2) Disconnect the motor from the rotation so that the substrate drive can turn
freely.
3) Push the planetary with your hand. It should rotate freely for 3 to 5 revolutions
after one firm push. Rotation motion should be smooth.
4) If the rack does not rotate, or it is very hard to move, disassemble the planetary
and replace the bearings.
5) Reassemble the system and try again.
10.6
Mechanical Pump:
Problem: Rough out times are increasing; Auto regen program fails to complete;
mechanical pump pressure is high. Mechanical pump is not able to hold ultimate pressure.
Cause:
Low oil level. Mechanical pump seals bad.
Solution:
1) Place system in Manual Mode.
2) Close all valves and turn ON Mechanical pump.
3) Observe pressure on Denton DV-23 thermocouple controller. This controller is
used as a redundant pressure sensor. It is used to evaluate mechanical pump
performance.
4) The pressure should quickly go to less than 1 militorr (off the bottom of the
scale).
5) This is the baseline or ultimate pressure of the mechanical pump. The lowest
pressure that the mechanical pump can attain isolated from the rest of the
vacuum system.
6) If the ultimate pressure is above this reading, Check the oil level in the
mechanical pump. Refer to the operating manual. Add to or change the oil as
required.
7) The mechanical pump may require ballasting if the mechanical pump oil has
been contaminated. Refer to the operating manual for specific instructions.
10-7
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
8) If the oil level is correct and the oil is not contaminated, but the ultimate pressure
is still above 1 militorr contact Denton Vacuum (856-439-9100).
10.7
Substrate Heat:
DANGER HIGH VOLTAGE!
Problem:
Heat lamps do not turn on. No heat control.
Cause:
A. Fuse blown.
B. Contactor #1 is not closing.
C. SCR #1 LED’s not glowing in proportion to output.
D. Lamp is burnt out.
E. Thermocouple defective or not connected.
NOTE: Verify that temperature setpoint is higher than current temperature
proceeding.
before
Solutions (Cause A):
1) Sheet #3 of the wiring diagram contains the heater circuit diagram.
2) Locate heater fuse in the control rack.
3) Shut power to the heaters OFF before proceeding.
4) Remove the fuse and check it with an ohm meter. If blown, replace.
Solutions (Cause B):
1) Sheet #3 of the wiring diagram contains the heater circuit diagram.
2) Toggle the heater power pushbutton on the Overview page. Check Rack 0, Slot
5, Pin 3 of the PLC. Verify that the “2” LED on the PLC toggles with the
pushbutton.
3) If LED does not toggle, use an ohm meter to verify the heater interlock string on
Sheet #3 of the wiring diagram.
4) If LED toggles, replace contactor.
10-8
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Solutions (Cause C):
The silicon control rectifier (SCR) controller is a solid state device designed to control a
large AC power level with a small DC control signal.
The input of the SCR is 208V AC; protected by a fuse to limit the current that will be seen
by the SCR controller. As the DC signal to the gate of the SCR increases so does the
output of the SCR controller. The SCR controller is about 95% efficient. This means for a
given input, the output voltage will achieve 95% of the actual input voltage. AN SCR has
a preset gain and span set on it. If these parameters are readjusted, it will limit the
control range of the SCR either at the low end or the high end.
Besides being able to control the SCR with an external 0 - 10 Volt DC source, it can be
controlled by an internal signal from it’s own source of power. This can be done by
removing the 0 - 10 Volt DC signal from the “W” and “CCW” terminals, then attaching a
1K ohm potentiometer to the “CW”, “W”, and “CCW” terminals of the SCR. An SCR
controller has one unusual property. If there is no “LOAD” attached to the output, the
SCR will pass full voltage no matter where the DC control voltage is set.
1) Sheet #3 of the wiring diagram contains the heater circuit diagram.
2) Use a DC Voltmeter on terminals W and CCW on the SCR. Red lead on W and
black lead on CCW.
3) If a minus (-) voltage is displayed, reverse the wires on the W and CCW
terminals.
4) If there is no voltage at the SCR, check Rack 0, Slot 10 of the PLC for 0-10 Volt
DC output.
5) If there is a 0-10 Volt signal at Rack 0, Slot 10 of the PLC, replace the SCR.
Solutions (Cause D):
1) Use Ohm meter to test continuity in individual heater lamps.
2) Replace heater lamp if it is defective.
Solutions (Cause E):
1) Verify thermocouple connections with Ohm meter. Reconnect or repair if
necessary.
2) Use Ohm meter to test continuity in thermocouple.
3) Replace thermocouple if it is defective.
10-9
DARTMOUTH COLLEGE, JOB # 43137
TROUBLESHOOTING
10.8
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
Summary:
Steps for troubleshooting should follow a logical order.
Vacuum systems are constructed from many different vendor parts and subassemblies:
everything from electrical valves to electron beam guns. Each subsystem is supplied with
a manual of operation. Familiarize yourself with all the operating manuals supplied with
the vacuum system. Refer to these manuals for trouble shooting procedures on the
individual equipment in question.
This manual reviews the most common problems experienced with similar vacuum
systems. Possible causes are described and solutions are presented in a step-by-step
procedure. Most problems can be identified and corrected with a similar approach.
If after a reasonable time the problem cannot be identified, call Denton Vacuum (856439-9100) to assist with troubleshooting and repair. We can also provide system training
to facilitate system maintenance and reduce down time.
10-10
DARTMOUTH COLLEGE, JOB # 43137
LIST OF ELECTRICAL SCHEMATICS
11.
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
List of Electrical Schematics
0) Cover Page
1) Power Distribution
EXP140201-43137.DWG
2) Power Distribution
EXP140202-43137.DWG
3) Power Distribution
EXP140203-43137.DWG
4) Heat Control
EXP140302-43137.DWG
5) Heat Control
EXP140301-43137.DWG
6) Low Voltage Control Wiring Diagram
EXP140401-43137.DWG
7) Low Voltage Control Wiring Diagram
EXP140402-43137.DWG
8) Vacuum Control Gauging
EXP140501-43137.DWG
9) Vacuum Control Gauging
EXP140502-43137.DWG
10) Spare
EXP140601-43137.DWG
11) Substrate Rotation Control
EXP140701-43137.DWG
12) Pumping Control
EXP140801-43137.DWG
13) Pumping Control
EXP140802-43137.DWG
14) Pumping Control
EXP140803-43137.DWG
15) Gas Control
EXP140901-43137.DWG
16) Gas Control
EXP140902-43137.DWG
17) Source Control
EXP141001-43137.DWG
18) Source Control
EXP141002-43137.DWG
19) Source Control
EXP141003-43137.DWG
20) Source Control
EXP141004-43137.DWG
21) Deposition Control
EXP141101-43137.DWG
22) Deposition Control
EXP141102-43137.DWG
23) Spare
EXP141201-43137.DWG
24) Glow Discharge Control
EXP141301-43137.DWG
11-1
DARTMOUTH COLLEGE, JOB # 43137
LIST OF ELECTRICAL SCHEMATICS
DENTON VACUUM LLC.
EXPLORER 14 CRYO SYSTEM
25) Glow Discharge Control
EXP141302-43137.DWG
26) Spare
EXP141401-43137.DWG
27) PLC Control
EXP141501-43137.DWG
28) PLC Control
EXP141502-43137.DWG
29) PLC Control
EXP141503-43137.DWG
11-2
DARTMOUTH COLLEGE, JOB # 43137
LIST OF MECHANICAL DRAWINGS
12.
DENTON VACUUM LLC
EXPLORER 14 CRYO SYSTEM
List of Mechanical Drawings
1) General Arrangement & Floor Plan
D-0131-173-002
2) Air Piping Assembly
D-0131-173-012
3) Water Piping Assembly
C-0131-173-014
4) Vacuum Piping Assembly
D-0131-173-013
5) Biasable Table w/ Welded Water Table
C-0044-017-008
6) Heater Assembly
B-0131-073-015
7) 2" MAK Vertical Dimensions
L200DIMV
12-1
DARTMOUTH COLLEGE, JOB # 43137
SPARE PARTS LISTS
13.
DENTON VACUUM LLC
EXPLORER 14 CRYO SYSTEM
Spare Parts Lists (NOT Included – for Reference Only)
SPARE PARTS LIST
8033-513
Dartmouth College
Explorer 14 Cryo System
PART NO.
DESCRIPTION
J # 43137
LOCATION
QTY.
GSK002-0015
COPPER GASKET
CHAMBER
2
GLS001-0007
SIGHT GLASS
CHAMBER
1
ORG004-0214
O-RING
DOOR
1
ORG004-0125
O-RING
DOOR
1
VFT002-0078
O-RING
CHAMBER
1
VFT002-0002
C-RING
CHAMBER
1
VFT002-0003
C-RING
CHAMBER
1
GSK002-0010
COPPER GASKET
CHAMBER
1
GASKET NICKEL
CHAMBER
1
ORG005-0011
SEAL U-CUP
ROTATION
1
ORG004-0057
O-RING
ROTATION
1
BSH001-0003
BRUSH
ROTATION
2
CRU001-0013
ELECTRODE
ROTATION
4
LMP001-0016
LAMP 1000W
HEATER ASSY
2
FTG010-0003
13-1
DARTMOUTH COLLEGE, JOB # 43137
SPARE PARTS LISTS
DENTON VACUUM LLC
EXPLORER 14 CRYO SYSTEM
SPARE PARTS LIST
Dartmouth College
Explorer 14 System
PART NO.
FUS001-0089
FUS001-0090
FUS001-0091
FUS001-0092
FUS001-0023
FUS001-0058
FUS001-0024
FUS001-0025
FUS001-0026
FUS001-0027
FUS001-0080
DESCRIPTION
1/4A, 250V, TIME DELAY,
MIDGET
1/2A, 250V, TIME DELAY,
MIDGET
1A, 250V, TIME DELAY,
MIDGET
2A, 250V, TIME DELAY,
MIDGET
5A, 250V, TIME DELAY,
MIDGET
10A, 250V, TIME DELAY,
MIDGET
15A, 250V, TIME DELAY,
MIDGET
20A, 250V, TIME DELAY,
MIDGET
25A, 250V, TIME DELAY,
MIDGET
30A, 250V, TIME DELAY,
MIDGET
40A, 600V, TIME DELAY, J
TYPE
13-2
LOCATION
J# 43137
QTY.
1
3
5
5
3
6
2
2
0
0
0